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Investigation Of Injection Molding Process For High Precision Polymer Lens Manufacturing

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Investigation Of Injection Molding Process For High Precision Polymer Lens Manufacturing

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Author : Chunning Huang
language : en
Publisher:
Release Date : 2008

Investigation Of Injection Molding Process For High Precision Polymer Lens Manufacturing written by Chunning Huang and has been published by this book supported file pdf, txt, epub, kindle and other format this book has been release on 2008 with Injection molding of plastics categories.

Abstract: Injection molding polymer optical components have long been used for its high volume, low cost and lightweight capability over traditional glass optics. However, the process has not been readily accepted in precision optical fabrication industry because several difficult issues such as geometry deviation, inhomogeneous index distribution, birefringence and freeform fabrication have hindered the implementation of injection molding process in high precision optical applications. This dissertation research was an attempt to create a methodology for injection molding process for high precision polymer lens manufacturing. The study included both experimental approach and numerical modeling in order to identify the proper polymer lens manufacturing processes. The scope of this research involved in both fundamental and systematic investigation in optical design, mold and lens fabrication, as well as optical metrology issues related to polymer lens manufacturing to obtain precision macro and micro polymer freeform optics with accurate geometry and proper optical performance by the state-of-the-art mold fabrication and molding technology. With the aid of DOE (design of experiment) and DEA (data envelopment analysis) methods, the critical process parameters were narrowed down and the optimal conditions were determined for lens geometry compensation. The mold compensation methodology was developed based on advanced freeform measurement and data analysis technology and slow tool servo freeform mold fabrication. The effects of the process parameters on optical performance such as birefringence, index distribution and surface scattering were carefully studied by theoretical and empirical analysis. Due to the complexity of the injection molding process, single process condition cannot fulfill all the requirements for lens quality, therefore balanced process parameters need to be selected as a compromise for desired specifications. Moreover, fabrication of macro Alvarez lens, micro Alvarez lens array, diffractive lens and Fresnel lens has proven that the advanced mold fabrication and injection molding process can provide an easy and quick solution for freeform optics. In addition, simulation with Moldflow MPI6.1 was implemented to verify the experiment results and the prediction of the simulation results was validated using experiment results. Experimental results also showed that injection molding process is capable for precision optics manufacturing with accurate mold compensation and process control.

Injection Molding

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Author : Phoebe H. Kauffer
language : en
Publisher:
Release Date : 2011

Injection Molding written by Phoebe H. Kauffer and has been published by this book supported file pdf, txt, epub, kindle and other format this book has been release on 2011 with Injection molding of plastics categories.

Injection moulding is one of the most versatile and important manufacturing processes, capable of mass-producing complicated plastic parts in a variety of complex shapes with high dimensional precision. It is a major processing technique for converting thermoplastic and thermosetting materials with the aid of heat and pressure into complicated parts, consuming world-wide approximately 32% of all plastics. This book presents current research data in the study of injection moulding from across the globe, including an overview of injection moulding as a manufacturing technique for pharmaceutical applications; melt/solid weldline in over injection moulding; metal injection moulding of Co for biomedical applications; and the application of ultrasonic technology in the injection moulding process.

Fabrication Of Complex Optical Components

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Author : Ekkard Brinksmeier
language : en
Publisher: Springer Science & Business Media
Release Date : 2012-09-14

Fabrication Of Complex Optical Components written by Ekkard Brinksmeier and has been published by Springer Science & Business Media this book supported file pdf, txt, epub, kindle and other format this book has been release on 2012-09-14 with Technology & Engineering categories.

High quality optical components for consumer products made of glass and plastic are mostly fabricated by replication. This highly developed production technology requires several consecutive, well-matched processing steps called a "process chain" covering all steps from mold design, advanced machining and coating of molds, up to the actual replication and final precision measurement of the quality of the optical components. Current market demands for leading edge optical applications require high precision and cost effective parts in large volumes. For meeting these demands it is necessary to develop high quality process chains and moreover, to crosslink all demands and interdependencies within these process chains. The Transregional Collaborative Research Center "Process chains for the replication of complex optical elements" at Bremen, Aachen and Stillwater worked extensively and thoroughly in this field from 2001 to 2012. This volume will present the latest scientific results for the complete process chain giving a profound insight into present-day high-tech production.

Micro Injection Molding

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Author : Guido Tosello
language : en
Publisher: Carl Hanser Verlag GmbH Co KG
Release Date : 2019-06-11

Micro Injection Molding written by Guido Tosello and has been published by Carl Hanser Verlag GmbH Co KG this book supported file pdf, txt, epub, kindle and other format this book has been release on 2019-06-11 with Technology & Engineering categories.

"Micro Injection Molding" meets the need for a dedicated book dealing exclusively with micro injection molding and overcoming the challenges of managing and processing polymer materials at ultra-small scales. Micro injection molding is the primary process for the mass production of polymer components with critical dimensions in the sub-millimeter range; however, it is not just a simple downscaling of conventional injection molding, and specific material-process-product interactions must be understood in order to achieve near zero-defect net-shape micro molded products. Micro molding is typically associated with ultra-high accuracy and superior process capabilities. Micro molded products have dimensional tolerances down to the single-digit micrometer range and surface finish with roughness from the sub-micrometer down to a few nanometers range. Micro and nano-structured tool surfaces are reproduced with very high replication fidelity onto the polymer products. Micro injection molding is highly suitable for the manufacture of multifunctional micro components such as micro implants, microfluidic systems, polymer micro optical elements, and micro mechanical systems. This book provides engineers, project managers, researchers, consultants, and other professionals involved in precision polymer processing and micro manufacturing with a comprehensive, up-to-date, and detailed treatment of the main topics related to micro molding, from material and process technology to tooling, to key-enabling technologies, and multimaterial process variations. Contents: • Part 1 – Polymer Materials and Process Micro Technology: micro injection molding machines technology; micro molding process monitoring and control; polymer materials structure and properties in micro injection molding parts; surface replication in micro injection molding • Part 2 – Tooling Technologies for Micro Mold Making: micro machining technologies for micro injection mold making; ultra-precision machining technologies for micro injection mold making; surface treatment of mold tools in micro injection molding • Part 3 – Micro Molding Key-Enabling Technologies: vacuum-assisted micro injection molding; modeling and simulation of micro injection molding; metrological quality assurance in micro injection molding; additive manufacturing for micro tooling and micro part rapid prototyping • Part 4 – Multimaterial Micro Processing: micro powder injection molding; multimaterial micro injection molding

Intelligent Optimization Of Mold Design And Process Parameters In Injection Molding

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Author : Mehdi Moayyedian
language : en
Publisher: Springer
Release Date : 2018-11-02

Intelligent Optimization Of Mold Design And Process Parameters In Injection Molding written by Mehdi Moayyedian and has been published by Springer this book supported file pdf, txt, epub, kindle and other format this book has been release on 2018-11-02 with Technology & Engineering categories.

This book describes an effective framework for setting the right process parameters and new mold design to reduce the current plastic defects in injection molding. It presents a new approach for the optimization of injection molding process via (i) a new mold runner design which leads to 20 percent reduction in scrap rate, 2.5 percent reduction in manufacturing time, and easier ejection of injected part, (ii) a new mold gate design which leads to less plastic defects; and (iii) the introduction of a number of promising alternatives with high moldability indices. Besides presenting important developments of relevance academic research, the book also includes useful information for people working in the injection molding industry, especially in the green manufacturing field.

Precision Injection Molding

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Author : Jehuda Greener
language : en
Publisher: Hanser Publications
Release Date : 2006

Precision Injection Molding written by Jehuda Greener and has been published by Hanser Publications this book supported file pdf, txt, epub, kindle and other format this book has been release on 2006 with Injection molding of plastics categories.

One of the key aspects of the production of high precision components is the need to meet extremely tight dimensional tolerances, typically in the submicron range, and maintain these tolerances over the practical lifetimes of the molded articles. In addition, as many of the precision components are utilized in various optoelectronic systems and devices, control of optical and electrical properties is often crucial. The strict control of dimensional and electro-optical properties requires a systematic reexamination of the conventional injection-molding process with special consideration of its impact on the dimensions and electro-optical characteristics of the molded article. This volume examines precision injection molding from different perspectives, covering materials, process and hardware aspects of the technology, with special emphasis on the dimensional integrity and stability of the molded components. Special topics covered in this volume include: dimensional stability of molded plastics, models for warpage development, compact disc molding, process control, crystallization phenomena in injection molding, micro-molding and microfluidics.

Fabrication Of Complex Optical Components

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Author : Ekkard Brinksmeier
language : en
Publisher: Springer Science & Business Media
Release Date : 2012-09-13

Injection Molding Handbook

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Author : D.V. Rosato
language : en
Publisher: Springer Science & Business Media
Release Date : 2012-12-06

Injection Molding Handbook written by D.V. Rosato and has been published by Springer Science & Business Media this book supported file pdf, txt, epub, kindle and other format this book has been release on 2012-12-06 with Technology & Engineering categories.

This third edition has been written to thoroughly update the coverage of injection molding in the World of Plastics. There have been changes, including extensive additions, to over 50% of the content of the second edition. Many examples are provided of processing different plastics and relating the results to critiCal factors, which range from product design to meeting performance requirements to reducing costs to zero-defect targets. Changes have not been made that concern what is basic to injection molding. However, more basic information has been added concerning present and future developments, resulting in the book being more useful for a long time to come. Detailed explanations and interpretation of individual subjects (more than 1500) are provided, using a total of 914 figures and 209 tables. Throughout the book there is extensive information on problems and solutions as well as extensive cross referencing on its many different subjects. This book represents the ENCYCLOPEDIA on IM, as is evident from its extensive and detailed text that follows from its lengthy Table of CONTENTS and INDEX with over 5200 entries. The worldwide industry encompasses many hundreds of useful plastic-related computer programs. This book lists these programs (ranging from operational training to product design to molding to marketing) and explains them briefly, but no program or series of programs can provide the details obtained and the extent of information contained in this single sourcebook.

Modern Manufacturing Processes

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Author : Muammer Koç
language : en
Publisher: John Wiley & Sons
Release Date : 2019-09-04

Modern Manufacturing Processes written by Muammer Koç and has been published by John Wiley & Sons this book supported file pdf, txt, epub, kindle and other format this book has been release on 2019-09-04 with Technology & Engineering categories.

Provides an in-depth understanding of the fundamentals of a wide range of state-of-the-art materials manufacturing processes Modern manufacturing is at the core of industrial production from base materials to semi-finished goods and final products. Over the last decade, a variety of innovative methods have been developed that allow for manufacturing processes that are more versatile, less energy-consuming, and more environmentally friendly. This book provides readers with everything they need to know about the many manufacturing processes of today. Presented in three parts, Modern Manufacturing Processes starts by covering advanced manufacturing forming processes such as sheet forming, powder forming, and injection molding. The second part deals with thermal and energy-assisted manufacturing processes, including warm and hot hydrostamping. It also covers high speed forming (electromagnetic, electrohydraulic, and explosive forming). The third part reviews advanced material removal process like advanced grinding, electro-discharge machining, micro milling, and laser machining. It also looks at high speed and hard machining and examines advances in material modeling for manufacturing analysis and simulation. Offers a comprehensive overview of advanced materials manufacturing processes Provides practice-oriented information to help readers find the right manufacturing methods for the intended applications Highly relevant for material scientists and engineers in industry Modern Manufacturing Processes is an ideal book for practitioners and researchers in materials and mechanical engineering.

An Investigation On The Injection Moulding Process And Performance Of Polymer Polymer Composite Gears

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Author : Ramkumar Ramakrishnan
language : en
Publisher:
Release Date : 2017

An Investigation On The Injection Moulding Process And Performance Of Polymer Polymer Composite Gears written by Ramkumar Ramakrishnan and has been published by this book supported file pdf, txt, epub, kindle and other format this book has been release on 2017 with Gearing categories.

Investigation Of Injection Molding Process For High Precision Polymer Lens Manufacturing

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