Injection molding of parts characterized by large overall dimensions is a challenging task due to the rise of cavity pressure during the filling phase. Process limitations lead to oversized design solutions and cavity thicknesses that are greater than the structural properties required to the part. In this work, a novel approach to thickness reduction is proposed exploiting the thermal-insulation effect of mold surface coatings. The effects of different mold surface coatings on the melt flow resistance of polyethylene terephthalate was experimentally characterized. Then, the thermal boundary condition of a numerical injection molding simulation was calibrated and it was used to quantify the thickness reduction associated to each coating. The results show that mold surface coatings can be used to improve the design of injection molded parts by reducing their wall thickness.
Injection molding of thinner parts using mold surface coatings
Masato D.
;Sorgato M.;Piccolo L.;Lucchetta G.
2019
Abstract
Injection molding of parts characterized by large overall dimensions is a challenging task due to the rise of cavity pressure during the filling phase. Process limitations lead to oversized design solutions and cavity thicknesses that are greater than the structural properties required to the part. In this work, a novel approach to thickness reduction is proposed exploiting the thermal-insulation effect of mold surface coatings. The effects of different mold surface coatings on the melt flow resistance of polyethylene terephthalate was experimentally characterized. Then, the thermal boundary condition of a numerical injection molding simulation was calibrated and it was used to quantify the thickness reduction associated to each coating. The results show that mold surface coatings can be used to improve the design of injection molded parts by reducing their wall thickness.
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