Replication quality of micro structures in injection moulded thin wall parts using rapid tooling moulds

Meister, Steve; Seefried, Andreas; Drummer, Dietmar

doi:10.1007/s00542-015-2415-9

Cited by 9 publications

(5 citation statements)

References 19 publications

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“…The surface texture on the components is a replication of the grain pattern in the mold cavity, and to avoid variations in color and gloss it is important to have good replication of the grain pattern. Unfortunately, a large number of material and processing parameters affects the replication and a substantial number of investigations have therefore been carried out to improve the knowledge about robust injection moulding of textured components with high-aspect ratio [1][2][3][4][5][6][7][8]. In this study, the effect of texture, tool temperature, holding pressure and injection speed on surface texture replication of injection moulded PC-ABS (Polycarbonate-Acrylonitrile butadiene Styrene) samples and its relationship with measured gloss are investigated.…”

Section: Introductionmentioning

confidence: 99%

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Surface characterization and analysis of textured injection moulded PC-ABS automotive interior components

Reddy¹,

Krishna²,

Sjögren³

et al. 2023

Surf. Topogr.: Metrol. Prop.

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Automotive interior components are produced by injection moulding due to its cost effectiveness in mass production. The surfaces of these components are textured to control the appearance and other surface functional properties such as wear and scratch resistance. Key challenges lie in replicating the features of mould tool with high aspect ratio which are influenced by the polymer and large number of process variables. Hence, to control the aesthetic properties, it is important to improve the understanding of the replication of textured surfaces and its relationship with measured gloss. In this study, the surface topography of PC-ABS samples is investigated using coherence scanning interferometry. Replication of two types- coarse and fine grain surface texture are investigated to identify the effects of tool temperature, injection speed and holding pressure. Areal surface parameters are scrutinized for the quantitative characterization and discrimination of study samples surface topographies. The correlations between process parameters, measured gloss and areal surface parameters are discussed. The results show significant influence of process variables on the replication of surface topography and measured gloss. The grain pattern governed the set of surface parameters selected and the variation in gloss. The process variables are observed to influence different region or distribution of specific surface features represented by surface parameters.

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Section: Introductionmentioning

confidence: 99%

“…Background 1.1.1. Injection moulding process Earlier investigations on effect of tool temperature suggest higher replication of surface texture with higher tool temperature [3,7]. A high tool temperature leads to longer time for the plastic material to solidify and thereby longer time available for replication.…”

Section: Introductionmentioning

confidence: 99%

Surface characterization and analysis of textured injection moulded PC-ABS automotive interior components

Reddy¹,

Krishna²,

Sjögren³

et al. 2023

Surf. Topogr.: Metrol. Prop.

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“…In addition, the rapidly solidified surface layers take up a significantly larger proportion of the total flow cross-section compared to macroscopic components. This often leads to filling and replication problems of fine surface structures [ 34 ]. Among other things, this is attempted to be compensated by high mold temperatures [ 35 ] or high injection speeds [ 36 ].…”

Section: Introductionmentioning

confidence: 99%

High-Precision Thin Wall Bipolar Plates for Fuel Cell Applications via Injection Compression Molding with Dynamic Mold Temperature Control

et al. 2022

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In recent years, the demand for polymer compound solutions for the application of bipolar plates in polymer electrolyte membrane fuel cells (PEMFC) has increased continuously due to significant cost and lifetime advantages compared to metallic solutions. The main challenge of the compounds is the high filler content required to ensure sufficient electrical conductivity of the bipolar plates. The associated increase in viscosity and simultaneously increased thermal conductivity limit the conventional injection molding process in terms of achievable flow path length to wall thickness ratios (plate aspect ratio). In order to evaluate the extent to which highly modified electrically conductive polymer material systems can be processed into thin-walled and highly dimensionally stable bipolar plates, an injection compression molding process with dynamic mold temperature control (ICM-DT) has been developed. For this purpose, a compound was prepared from polypropylene (PP) and graphite-flakes. The compound was characterized with respect to the achieved filler content, the electrical conductivity, as well as the pressure- and temperature-dependent solidification range. The ICM-DT experiments were carried out by varying the maximum mold temperature and the compression force. In addition, the process was designed with multiple compression and decompression steps to account for a possible pressure-dependent solidification of the compound. The plates were characterized with respect to the achieved plate aspect ratio and the flow-path-dependent dimensional thickness stability. It was shown that the plate aspect ratio could be increased by up to 125% with the maximum filler content compared to conventional injection molding processes provided in the literature. With the multi-stage ICM-DT process, it was also possible to optimize the thickness dimensional stability with a maximum deviation of 3% over the flow path.

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“…This can be also used to minimize the reduction in tensile strength in parts, where weld lines are present [ 21 , 22 , 23 ]. Besides, the high cavity surface temperature is commonly used to improve surface quality (removal of weld lines’ presence, obtaining high-gloss surface, better replication of microstructure of the cavity surface) [ 6 , 11 , 23 , 24 , 25 , 26 , 27 , 28 ].…”

Section: Introductionmentioning

confidence: 99%

Application of Magnetic Concentrator for Improvement in Rapid Temperature Cycling Technology

2020

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The main method to improve the filling of the cavity by the polymer melt is to increase the mold temperature. Rapid temperature cycling (RTC) technologies have been used around the world for several years, improving the quality of injection molded parts with a slight extension of production time. The present work focuses on the application of induction heating technology in the injection molding process since it is the most effective and most intensively developing method of heating in modern RTC technologies. In this research, the application of the induction heating process for selected surfaces was investigated with particular emphasis on the dynamics of the process. The numerical simulations were used to study the influence of the number of coils, the distance between coils and cavity surface and the mold material was examined with and without the presence of a magnetic concentrator. According to the obtained results, several crucial conclusions were made: the efficiency of heating is directly correlated with the distance between the inductor and the mold surface, the presence of magnetic flux concentrator significantly improves the homogeneity of temperature distribution and heating efficiency, application of aluminum mold lowers the obtained surface temperature.

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Replication quality of micro structures in injection moulded thin wall parts using rapid tooling moulds

Cited by 9 publications

References 19 publications

Surface characterization and analysis of textured injection moulded PC-ABS automotive interior components

Surface characterization and analysis of textured injection moulded PC-ABS automotive interior components

High-Precision Thin Wall Bipolar Plates for Fuel Cell Applications via Injection Compression Molding with Dynamic Mold Temperature Control

Application of Magnetic Concentrator for Improvement in Rapid Temperature Cycling Technology

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