Efficient and Precise Micro-Injection Molding of Micro-Structured Polymer Parts Using Micro-Machined Mold Core by WEDM

Liao, Qianghua; Zhou, Chilou; Lu, Yanjun; Wu, Xiaoyu; Chen, Fumin; Lou, Yan

doi:10.3390/polym11101591

Cited by 15 publications

(8 citation statements)

References 26 publications

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“…The increased demand for micro-scale parts and devices is being met, in many cases, by the micro-injection molding of polymer parts [ 7 , 8 , 9 ]. However, part inspection is difficult, due to the micro-scale dimension in the micro-injection molding process.…”

Section: Introductionmentioning

confidence: 99%

Research on Quality Characterization Method of Micro-Injection Products Based on Cavity Pressure

et al. 2021

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The cavity pressure in the injection molding process is closely related to the quality of the molded products, and is used for process monitoring and control, to upgrade the quality of the molded products. The experimental platform was built to carry out the cavity pressure experiment with a micro spline injection mold in the paper. The process parameters were changed, such as V/P switchover, mold temperature, melt temperature, packing pressure, and injection rate, in order to analyze the influence of the process parameters on the product weight. The peak cavity pressure and area under the pressure curve were the two attributes utilized in investigating the correlation between cavity pressure and part weight. The experimental results show that the later switchover allowed the injection to proceed longer and produce a heavier tensile specimen. By comparing different cavity pressure curves, the general shapes of the curves were able to indicate different types of shortage produced. When the V/P switchover position is 10 mm, the coefficient of determination (R2 value) of part weight, for the peak cavity pressure and area under the curve, were 0.7706 and 0.8565, respectively. This showed that the area under the curve appeared to be a better process and quality indicator than the peak cavity pressure.

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Section: Introductionmentioning

confidence: 99%

Research on Quality Characterization Method of Micro-Injection Products Based on Cavity Pressure

et al. 2021

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“…The machining results, especially in terms of IFH, are of three configurations: (1) the inter-channels fins are approximately straight with good IFH values (Figure 7a-d), (2) the inter-channels fins are of appreciable height but slightly deflected at the tip region of the fins (Figure 7e-g), and (3) low heightened inter-channels fins with curly tips (Figure 7h-i). Liao et al [28] have stated that machining of single micro-feature is easier to produce with WEDM but the features arranged in a periodic order (micro-arrays) are difficult to produce via WEDM process. The low-speed wire-cut process has been recommended for producing micro-features of size ranging below 100 µm thickness.…”

Section: Analysis Of Interchannels Fin Height (Ifh)mentioning

confidence: 99%

“…WEDM can be easily used to cut the macro-sized gears but the cutting of miniaturized gear is relatively difficult [27]. Moreover, producing a single micro-feature through WEDM is simple but the cutting of repeated micro-features (micro-arrays) is reasonably difficult [28]. Miller et al [29] produced thin structures through WEDM and deformation in the thin section has been reported as the drawback.…”

Section: Introductionmentioning

confidence: 99%

WEDM of Copper for the Fabrication of Large Surface-Area Micro-Channels: A Prerequisite for the High Heat-Transfer Rate

et al. 2020

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To get the maximum heat transfer in real applications, the surface area of the micro-features (micro-channels) needs to be large as possible. It can be achieved by producing a maximum number of micro-channels per unit area. Since each successive pair of the micro-channels contain an inter-channels fin, therefore the inter-channels fin thickness (IFT) plays a pivotal role in determining the number of micro-channels to be produced in the given area. During machining, the fabrication of deep micro-channels is a challenge. Wire-cut electrical discharge machining (EDM) could be a viable alternative to fabricate deep micro-channels with thin inter-channels fins (higher aspect ratio) resulting in larger surface area. In this research, minimum IFT and the corresponding machining conditions have been sought for producing micro-channels in copper. The other attributes associated with the micro-channels have also been deeply investigated including the inter-channels fin height (IFH), inter-channels fin radius (IFR) and the micro-channels width (MCW). The results reveal that the inter-channels fin is the most critical feature to control during the wire electrical discharge machining (WEDM) of copper. Four types of fin shapes have been experienced, including the fins: broken at the top end, deflected at the top end, curled bend at the top, and straight with no/negligible deflection.

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“…However, the silk-screen printing process was complex, and the generated ink volatilization polluted the environment [5]. Previous studies have shown that the micro-structure was first machined on the surface of a mold and then was replicated to the polymer workpiece surface to rapidly fabricate the micro-structured polymer diffusion plate by hot pressing or micro injection molding technologies [6,7] to realize the mass production and manufacture of micro-structured diffusion plates. Due to its simple manufacturing process and low production cost, micro injection molding is suitable for the mass production and manufacture of micro-structured polymers.…”

Section: Introductionmentioning

confidence: 99%

Fabrication of Micro-Structured LED Diffusion Plate Using Efficient Micro Injection Molding and Micro-Ground Mold Core

Luo

et al. 2020

Polymers

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In this paper, a new style of micro-structured LED (light-emitting diode) diffusion plate was developed using a highly efficient and precise hybrid processing method combined with micro injection molding and micro-grinding technology to realize mass production and low-cost manufacturing of LED lamps with excellent lighting performance. Firstly, the micro-structured mold core with controllable shape accuracy and surface quality was machined by the precision trued V-tip grinding wheel. Then, the micro-structured LED diffusion plate was rapidly fabricated by the micro injection molding technology. Finally, the influences of micro injection molding process parameters on the illumination of the micro-structured diffusion plate were investigated. The simulated optical results show that the illumination of the micro-structured diffusion plate can achieve a maximum value when the V-groove depth and V-groove angle are designed to be 300 μm and 60°, respectively. The experimental results indicate that the developed micro-structured diffusion plate may improve the illumination by about 40.82% compared with the traditional diffusion plate. The prediction accuracy of the designed light efficiency simulation method was about 90.33%.

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Efficient and Precise Micro-Injection Molding of Micro-Structured Polymer Parts Using Micro-Machined Mold Core by WEDM

Cited by 15 publications

References 26 publications

Research on Quality Characterization Method of Micro-Injection Products Based on Cavity Pressure

Research on Quality Characterization Method of Micro-Injection Products Based on Cavity Pressure

WEDM of Copper for the Fabrication of Large Surface-Area Micro-Channels: A Prerequisite for the High Heat-Transfer Rate

Fabrication of Micro-Structured LED Diffusion Plate Using Efficient Micro Injection Molding and Micro-Ground Mold Core

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