Injection Moulding Technology Research Articles

Advances in Injection Molding and Extrusion Technology (2) 2. Technological Progress in Injection Molding Processes

Advances in Injection Molding and Extrusion Technology (2) 2. Technological Progress in Injection Molding Processes

Mechanical characterisation of Aerosil-polycarbonate-based ceramic nanocomposites: 3D printing versus injection moulding technology

The 3D printing of composite materials especially, nanocomposites, is an essential step in exploring new perspectives for the applications of organic matrix composite materials for industrial applications. In this work, the effect of ceramic nanofillers on the mechanical properties of a thermoplastic matrix is studied using different wt% of nanofillers (AEROSIL). The results showed that the increase in the wt% of AEROSIL resulted in an increase in the mechanical properties in terms of hardness, stiffness, ductility, and tensile strength. Moreover, these samples were 3D printed and were compared with the samples prepared by conventional injection moulding. The comparison characterized the influence of the manufacturing method on the mechanical performance of materials. Although there was very little behavior difference in both samples, the 3D-printed samples showed a weight reduction. This has broadened the possible applications of this material and technique in areas where weight is of utmost significance.

Time and Spatially Resolved Operando Small-Angle X-ray Scattering Measurements during Injection Moulding of Plastics

We recently introduced the possibility of performing operando small-angle X-ray scattering measurements using a novel industrially relevant injection moulding system for plastics. We show that useful time-resolving measurements can be performed with a time-cycle of 1 s and highlight the possible steps to reduce this to 0.5 s. We show how we can use the transmission measurements to provide a time marker when plastic first enters the mould cavity in the region probed by the incident X-ray beam. We show the opportunities provided by this experimental stage mounted on the NCD-SWEET beamline at ALBA to probe the reproducibility of the injection moulding system on different scales. The design of the equipment allowed for the development of the structure and the morphology to be evaluated in different parts of mould cavity, and we evaluated any differences in a rectangular mould cavity. We identified future prospects for this equipment in terms of novel mould heating and cooling systems and the opportunities for quantitatively evaluating radical approaches to injection moulding technology.

Design and Manufacturing of Soft Grippers for Robotics by Injection Molding Technology

Design and Manufacturing of Soft Grippers for Robotics by Injection Molding Technology

RECYCLED PA 12 EXCLUDED FROM PROCESSING BY ADDITIVE TECHNOLOGIES

The ecological and economical treatment of derivatives from non-renewable sources is a current trend in the development of polymer systems, which supports global activities leading towards a sustainable environment. This article, therefore, deals with the effective management of powdered waste material (PA 12), which is no longer usable for additive technologies. Throughout recycling process, the material was modified and optimised for injection moulding technology, and transformed into pellets in the next step. The resulting thermoplastic material has a wide application potential, especially with regard to its very good mechanical and physical properties, which are evaluated in this contribution. The advantages of the resulting polymer are based, among other things, on the economic aspect, whereby a material with the nature of a structural plastic will be more available compared to plastics from an analogous category.

Structure and Properties of Ti3AlC2-SiC and Ti3AlC2-TiC Materials Obtained by Powder Injection Molding Technology

Powder injection melting (PIM) and material extrusion additive manufacturing (MEAM) are promising production technologies that allow us to obtain products from modern composite materials. These technologies make it possible to obtain products of complex shape from ceramic composite materials, which is a non-trivial task. A highly filled polymer feedstock is used as a source material in such technologies. In this work, a study of the structures and properties of samples obtained from SiC-Ti3AlC2 and TiC-Ti3AlC2 feedstocks by the PIM method was performed. The main purpose of this work was to study the influence of the powder compositions in feedstocks on the rheological properties and the structures of the obtained samples, as well as to determine the sintering parameters of samples of these compositions. In the future, it is planned to use the received and studied feedstocks in material extrusion additive manufacturing (MEAM). It was found that the investigated compositions had different MFI values depending on the composition. The effect of the sintering parameters on the structure and properties was shown. During the sintering of SiC-Ti3AlC2 ceramics in the temperature range of 1200–1400 °C in a vacuum, the main components of the mixture interacted with the formation of Ti3SiC2 and TiC. For materials of the TiC-Ti3AlC2 composition, partial oxidation of the material and the formation of titanium and aluminum oxides was observed.

Overview of MIM Technology Development in the Last 25 Years through Our μ-MIM Technology

It was a great honour for us to receive the 59th technical achievement award of Japan Society of Powder and Powder metallurgy (JSPM). We presented an overview of the metal injection moulding (MIM) technology development over 25 years of experience and future trends through our originally developed μ-MIM technology in the annual spring meeting of JSPM 2022, which are summarised in this paper.The μ-MIM technology is developed for especially small size metal parts with strict dimensional tolerances. We have focused only on a small complex designed metal part production in a net shaping, thus, the trend related to MIM parts larger than 50 mm in size is not covered. We have also joined the Micro Manufacturing Association in Japan since its establishment in 2018, which promotes micro parts manufacturing technology to the world. The demand increment of micro parts in various industries is never slowdown thus our μ-MIM technology overview might be instructive for both powder metallurgy and micro parts manufacturing interests.

Structural features of near equiatomic FeCo-2V semi-hard magnetic alloy prepared by MIM technology

The structural properties of a magnetically semi-hard near equiatomic FeCo-2wt%V (FeCoV) alloy produced by Powder Injection Moulding (PIM) (option by fine metal powder - Metal Injection Moulding (MIM) technology) were investigated in this paper. Starting granulate was prepared by mixing FeCoV powder with a low-viscosity binder. After injection, the green samples were first treated with a solvent and then thermally with the same aim of removing the binder. MIM technology was completed by high-temperature sintering for 3.5 hours at temperatures from 1370 OC to 1460 OC in a hydrogen atmosphere, which provides the necessary magnetic and mechanical characteristics. The influence of sintering temperature was investigated concerning the aspects of the processes of structural transformation by the methods of X-ray diffraction (XRD) and scanning electron microscopy (SEM). The appearance of an intense diffraction peak of the ?'-FeCo phase (crystal structure type B2) was registered for all investigated samples. Structural parameters particle size Dmax, Feret X, and Feret Y exhibit constant increase with increase of sintering temperature.

Development of New Foam Injection Molding Technology and Its Potential

Development of New Foam Injection Molding Technology and Its Potential

A Review of Metal Injection Moulding on WC-Co Cemented Carbide Comprised of Grain Growth Inhibitors (GGI)

This paper aims to provide a summary of metal injection moulding technologies utilising cemented WC-Co carbides comprised of grain growth inhibitors (GGI). The advanced manufacturing of metal injection moulding (MIM) has the ability to produce cement nanostructured carbides. In addition, the nature of the feedstock plays a crucial role when manufacturing a defect-free component at each point of the MIM phase, thus the interactions between the metal powder and the binder combining, moulding, and debinding are important to be recognised. The primary objective of this analysis is to investigate the characterization of feedstock to form a homogenous mixture. There are five criteria to classify features of the feedstock which include powder characteristics, binder composition, powder content ratio, mixing cycle, and approaches to palletization. Not only that, the feedstock must meet specific criteria; higher powder loading with excellent flowability by the rheological approaches. The second goal of the research is to re-evaluate feedstock’s flow properties in relation to rheological activity in terms of index flow behaviour (n), activation energy (E), and mouldability (α). MIM practitioners have continued to underestimate erratic product quality, including inadequate regulation, distortion, and internal and external defects. These defects can arise in the early processing phases, but often occur only after sintering or debinding. The approaches are also challenging to provide. This chapter includes a description of MIM defects. Explanations are listed and recommendations are provided for these defects.

Effect of de-sizing on the structural and mechanical properties of carbon fiber reinforced polypropylene composites molded by the novel direct fiber feeding injection molding technology

Carbon fiber reinforced thermoplastic composites are rapidly emerging as alternative materials for auto parts due to recyclability, excellent stiffness, and strength to weight ratio. In the present study, the influence of carbon fiber de-sizing on the structural and mechanical properties of the sized and de-sized Carbon Fiber Reinforced Polypropylene (CFPP) composites molded by the recently developed novel Direct Fiber Feeding Injection Molding technology was studied. The effect of carbon fiber de-sizing on the structural properties was studied from the fiber dispersion status, fiber orientation factor, fiber volume fraction, and the fiber length. The surface morphology of the sized and de-sized carbon fibers was studied from the Scanning Electron Microscopy (SEM) and Atomic Force Microscope images. The static mechanical properties were studied based on the tensile tests at different loading rate and temperature. The Dynamic Mechanical Analysis tests were conducted to analyze the dynamic viscoelastic behavior of the sized and de-sized CFPP composites. The SEM images were used to observe the failure mechanism. The preliminary results indicated that de-sized composites had better fiber dispersion as compared to the sized CFPP composites. It was found that de-sizing the carbon fiber surface does not significantly affect the carbon fiber length, fiber volume fraction, and fiber orientation in the CFPP composites. Also, the de-sized composites showed better static and thermodynamic mechanical properties caused by the enhanced fiber matrix interaction in CFPP composites as compared to the sized CFPP composites. [Formula: see text]

Development and Application of High-gloss Injection Molding Technology

High-gloss injection molding technology is a new green injection molding technology based on dynamic mold temperature control strategy. Compared with the traditional injection molding technology, this technology can obviously improve the surface quality of products, and obtain high quality products with high gloss and no weld line. This paper introduces the principle and technological characteristics of high-gloss injection molding, analyzes the key technology and development of high-gloss injection molding. The key technologies of high-gloss injection molding mainly include high-gloss molding material, high-gloss mold, mold temperature control system, etc. Finally, the existing problems of high-gloss injection molding technology are analyzed, and the breakthrough direction in the field of injection molding in the future is proposed.

High-Q High Power Tunable Filters Manufactured With Injection Molding Technology

This paper presents the first demonstration of injection molding technology to enable large-scale mass manufacturing of high-performance tunable microwave filters to meet the growing needs of 5G small cell stations. This is the first time that a tunable filter satisfies all four of the following requirements simultaneously: low manufacturing cost, high quality factor, wide tuning range, and high power handling. Exhaustive research exists on the use of polymers for 3D microwave device manufacturing; nonetheless, mass-production technologies, such as injection molding, can provide low costs without compromising performance. The proposed bandpass filter implementation uses a tunable evanescent-mode cavity resonator injection molded with an acrylonitrile-butadiene-styrene thermoplastic polymer. In addition, changing the critical gap size over the resonator’s post using a commercial microactuator provides frequency tuning. The measured filter achieves an 86% tuning range from 2.8 – 5.2 GHz with a state-of-the-art measured unloaded quality factor <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"> <tex-math notation="LaTeX">$Q_{u}$ </tex-math></inline-formula> of 1548 – 2573. The filter has a measured insertion loss of 0.06 - 0.1 dB with a fractional bandwidth from 7.6 - 8.4% across the entire tuning range. Moreover, for the first time in this manufacturing technology implementation, a bandpass filter is demonstrated with power handling capabilities beyond 100 W. The manufactured device demonstrates the significant potential of this technology for the scale-up manufacturing of reconfigurable high- <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"> <tex-math notation="LaTeX">$Q$ </tex-math></inline-formula> RF filters without compromising the performance.

Design of a novel midstream fluid waste sample collection device for patients

Reducing the contamination rates in mid-stream urine samples is a challenge. A novel design for a mid-stream urine sample collection device, which uses a novel mechanism to separate the mid-stream flow from the fore-stream and end-stream flows based on flow speed, is presented. The device, supplied in two parts, is designed to be clipped to a toilet and used in a seated position, which improves ease of use for disabled patients. As there is no mixing of the flow types during use, it is hypothesised that contamination rates should be lower than many competing designs. The all-polymer design is easy to use by both men and women, due to the addition of a form-fitting funnel and is designed to collect samples directly into containers of the same standard currently issued, allowing easy and hygienic collection. Due to its complex shape, the main body of the device is produced by a non-conventional injection moulding process. The holder can be produced using standard injection moulding technology. The two parts are designed to be assembled together by the user by means of a simple interference fit, which removes the cost of assembly altogether.

Development of Ceramic Items Injection Moulding Technology Using Computer Modeling

Development of Ceramic Items Injection Moulding Technology Using Computer Modeling

Problems and Constraints Involved in the Injection Moulding Process of Biocomposites: A Review

Biocomposite materials have revolutionized the engineering field, predominantly in manufacturing applications, where these materials were widely used as an alternative to the metal-based structural body or component. Since conventional materials have caused various pollution problems to the ecosystem, innovative efforts have been taken to develop the based product on natural materials composites but presently are not fully explored yet. Most issues raised are due to the lack of expertise in addressing some of the problems and constraints related to preparing feedstock materials involved in the injection moulding technique. The injectability process of the biocomposite material significantly depends on the early stage of feedstock preparation. The preparation steps should be considering the detailed characterization of the composite material, the effectiveness of the mixing method, the identification of the feedstock's flowability properties, and the appropriate processing parameters used. This review manuscript has a significant contribution to researchers interested in furthering the application of biocomposite-based materials, particularly in plastics injection moulding technology for manufacturing and processing engineering.

Comparative Analysis of Polypropylene Component manufactured by FDM and Injection Molding Technology

Comparative Analysis of Polypropylene Component manufactured by FDM and Injection Molding Technology

Injection process parameter analysis of metal injection molding for green part orthopedic implants

Based on Permenkes RI No. 86 of 2013 the need for orthopedic implants in the jaw / face is increasing. In orthopedics, implants are devices that are placed in place of bone to support fractures. Referring to the statement, Balai Besar Logam dan Mesin (BBLM) conducted research on the manufacture of orthopedic implant products for the face using Metal Injection Molding (MIM) technology. MIM is a combination of the characteristics of Powder Metallurgy and Plastic Injection Molding for the production of complex metal components. The injection process is a major factor that needs to be considered to prevent injection defects including incomplete fill defects in order to proceed to the post-molding process. Based on this, it is necessary to simulate and analyze process parameters to find the maximum process parameters in order to prevent incomplete fill defects. The analysis was carried out using injection molding simulation software, namely Sigmasoft, to the previously obtained design, with a variation setting of the filling temperature value of 170°C-190°C and filling time of 0.5s-2.5s. Variations in values are processed to obtain a combination of parameter settings analyzed. The simulation software generates filling pressure values and filling percentages in the mold cavity. Demonstrate optimal parameters for green part orthopedic implants with Catamold 316L feedstock. The optimal injection operating parameters are at a melting temperature of 180°C, filling time of 1s and filling pressure of 700 bar.

Simultaneously achieving self-toughening and self-reinforcing of polyethylene on an industrial scale using volume-pulsation injection molding

It is critical and difficult for production of large polymer parts using injection molding method to simultaneously achieve both good flowability and mechanical properties. Volume-Pulsation Injection Molding (VPIM) technology, exerting a high-amplitude vibration force field during the entire injection molding process, can be exploited to address this challenge, on an industrial scale. Through orientation of macromolecules with vibration forces during injection molding, mechanical properties of polymers can be improved at low cost without sacrificing flowability. In this study, employing VPIM technology, self-toughening and self-reinforcing of high-density polyethylene (HDPE) were realized while maintaining satisfactory flowability. Comparing with those of the convention injection molding (CIM) samples @ 210 °C, impact and yield strengths of the VPIM samples @ 0.7 Hz-210 °C were increased by 782.93% and 14.25%, respectively. According to crystal morphologies, shish-kebabs were formed in intermediate layer, leading to a remarkable enhancement in mechanical properties. Injection temperature and processing frequency had an influence on the shish-kebab structure and the intermediate layer thickness, thereby determining mechanical properties. These analysis results were supported by the evidence from impact-fractured surface morphology, 2D-SAXS, 2D-WAXD, and DSC. The response law of crystal structure and morphology to the vibration flow field was proposed to uncover the influence of processing conditions on material properties.

Injection moulding of porous MAX phase Ti3SiC2 without using space-holder

Ti3SiC2 is one of the most studied MAX phase due to its unique combination of metallic and ceramic like properties. In this work, Powder Injection Moulding (PIM) is proposed as a new processing route to manufacture porous MAX phase Ti3SiC2, without the need of a space holder. The main goal of this work is to broaden MAX phase application fields through powder injection moulding technology. In depth characterization of all process stages has been done to control porosity in the final parts. Self-synthesized powders were mixed with a multicomponent binder for the production of sustainable feedstocks. The binder selection was carried out considering the design of a process with the reduction of the carbon footprint. In this sense, the binder consists of a combination of water soluble and low CO2 emission polymers. Feedstocks produced exhibit good properties for injection moulding. Critical solid loading (52 vol%) and a set of debinding debinding conditions has been determined for a two-step process without producing any defects in the samples. In addition, sintering parameters have been adjusted to successfully achieve porous MAX phase samples.