Sample records for injection molding method
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Graf, Neil J; Bowser, Michael T
2013-10-07
Two different fabrication methods were employed to fabricate micropumps with different cross-sectional channel geometries. The first was to fabricate rectangular cross-sectional microchannel geometries using the well known fabrication method of replica molding (REM). The second, and far less utilized fabrication technique, was to create microchannel molds using an in-house fabricated handheld micro injection molding apparatus. The injection mold apparatus was designed for use with elastomeric room temperature vulcanization (RTV) polymers, as opposed to most other injection molding machines, which are designed for use with thermoplastic polymers. The injection mold's bottom plate was used as a microchannel molding template. The molding template was created by threading a small-diameter wire (150 μm or less) through the injection mold's bottom plate, with subsequent adhesion and smoothing of a thin piece of aluminum foil over the wire-raised injection mold template. When molded against, the template produced a rounded/Gaussian-shaped PDMS microchannel. The design of the injection mold will be presented, along with a direct comparison for micropump performance metrics such as flow rate, valving characteristics, and maximum backpressures attainable for each of the respective micropump channel geometries.
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Investigation of micro-injection molding based on longitudinal ultrasonic vibration core.
Qiu, Zhongjun; Yang, Xue; Zheng, Hui; Gao, Shan; Fang, Fengzhou
2015-10-01
An ultrasound-assisted micro-injection molding method is proposed to improve the rheological behavior of the polymer melt radically, and a micro-injection molding system based on a longitudinal ultrasonic vibration core is developed and employed in the micro-injection molding process of Fresnel lenses. The verification experiments show that the filling mold area of the polymer melt is increased by 6.08% to 19.12%, and the symmetric deviation of the Fresnel lens is improved 15.62% on average. This method improved the filling performance and replication quality of the polymer melt in the injection molding process effectively.
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Graf, Neil J.
2013-01-01
Two different fabrication methods were employed to fabricate micropumps with different cross-sectional channel geometries. The first was to fabricate rectangular cross-sectional microchannel geometries using the well known fabrication method of replica molding (REM).1 The second, and far less utilized fabrication technique, was to create microchannel molds using an in-house fabricated handheld micro injection molding apparatus. The injection mold apparatus was designed for use with elastomeric room temperature vulcanization (RTV) polymers, as opposed to most other injection molding machines, which are designed for use with thermoplastic polymers. The injection mold’s bottom plate was used as a microchannel molding template. The molding template was created by threading a small-diameter wire (150 μm or less) through the injection mold’s bottom plate, with subsequent adhesion and smoothing of a thin piece of aluminum foil over the wire-raised injection mold template. When molded against, the template produced a rounded/Gaussian-shaped PDMS microchannel. The design of the injection mold will be presented, along with a direct comparison for micropump performance metrics such as flow rate, valving characteristics, and maximum backpressures attainable for each of the respective micropump channel geometries. PMID:23917263
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Fundamentals of rapid injection molding for microfluidic cell-based assays.
Lee, Ulri N; Su, Xiaojing; Guckenberger, David J; Dostie, Ashley M; Zhang, Tianzi; Berthier, Erwin; Theberge, Ashleigh B
2018-01-30
Microscale cell-based assays have demonstrated unique capabilities in reproducing important cellular behaviors for diagnostics and basic biological research. As these assays move beyond the prototyping stage and into biological and clinical research environments, there is a need to produce microscale culture platforms more rapidly, cost-effectively, and reproducibly. 'Rapid' injection molding is poised to meet this need as it enables some of the benefits of traditional high volume injection molding at a fraction of the cost. However, rapid injection molding has limitations due to the material and methods used for mold fabrication. Here, we characterize advantages and limitations of rapid injection molding for microfluidic device fabrication through measurement of key features for cell culture applications including channel geometry, feature consistency, floor thickness, and surface polishing. We demonstrate phase contrast and fluorescence imaging of cells grown in rapid injection molded devices and provide design recommendations to successfully utilize rapid injection molding methods for microscale cell-based assay development in academic laboratory settings.
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Three-dimensional numerical simulation for plastic injection-compression molding
NASA Astrophysics Data System (ADS)
Zhang, Yun; Yu, Wenjie; Liang, Junjie; Lang, Jianlin; Li, Dequn
2018-03-01
Compared with conventional injection molding, injection-compression molding can mold optical parts with higher precision and lower flow residual stress. However, the melt flow process in a closed cavity becomes more complex because of the moving cavity boundary during compression and the nonlinear problems caused by non-Newtonian polymer melt. In this study, a 3D simulation method was developed for injection-compression molding. In this method, arbitrary Lagrangian- Eulerian was introduced to model the moving-boundary flow problem in the compression stage. The non-Newtonian characteristics and compressibility of the polymer melt were considered. The melt flow and pressure distribution in the cavity were investigated by using the proposed simulation method and compared with those of injection molding. Results reveal that the fountain flow effect becomes significant when the cavity thickness increases during compression. The back flow also plays an important role in the flow pattern and redistribution of cavity pressure. The discrepancy in pressures at different points along the flow path is complicated rather than monotonically decreased in injection molding.
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NASA Astrophysics Data System (ADS)
Shahbudin, S. N. A.; Othman, M. H.; Amin, Sri Yulis M.; Ibrahim, M. H. I.
2017-08-01
This article is about a review of optimization of metal injection molding and microwave sintering process on tungsten cemented carbide produce by metal injection molding process. In this study, the process parameters for the metal injection molding were optimized using Taguchi method. Taguchi methods have been used widely in engineering analysis to optimize the performance characteristics through the setting of design parameters. Microwave sintering is a process generally being used in powder metallurgy over the conventional method. It has typical characteristics such as accelerated heating rate, shortened processing cycle, high energy efficiency, fine and homogeneous microstructure, and enhanced mechanical performance, which is beneficial to prepare nanostructured cemented carbides in metal injection molding. Besides that, with an advanced and promising technology, metal injection molding has proven that can produce cemented carbides. Cemented tungsten carbide hard metal has been used widely in various applications due to its desirable combination of mechanical, physical, and chemical properties. Moreover, areas of study include common defects in metal injection molding and application of microwave sintering itself has been discussed in this paper.
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NASA Astrophysics Data System (ADS)
Park, Keun; Lee, Sang-Ik
2010-03-01
High-frequency induction is an efficient, non-contact means of heating the surface of an injection mold through electromagnetic induction. Because the procedure allows for the rapid heating and cooling of mold surfaces, it has been recently applied to the injection molding of thin-walled parts or micro/nano-structures. The present study proposes a localized heating method involving the selective use of mold materials to enhance the heating efficiency of high-frequency induction heating. For localized induction heating, a composite injection mold of ferromagnetic material and paramagnetic material is used. The feasibility of the proposed heating method is investigated through numerical analyses in terms of its heating efficiency for localized mold surfaces and in terms of the structural safety of the composite mold. The moldability of high aspect ratio micro-features is then experimentally compared under a variety of induction heating conditions.
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NASA Astrophysics Data System (ADS)
Steiner, Matthias
A statistically proven, series injection molding technique for ceramic components was developed for the construction of engines and gas turbines. The flow behavior of silicon injection-molding materials was characterized and improved. Hot-isostatic-pressing reaction bonded silicon nitride (HIPRBSN) was developed. A nondestructive component evaluation method was developed. An injection molding line for HIPRBSN engine components precombustion chamber, flame spreader, and valve guide was developed. This line allows the production of small series for engine tests.
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Comparison of Fit of Dentures Fabricated by Traditional Techniques Versus CAD/CAM Technology.
McLaughlin, J Bryan; Ramos, Van; Dickinson, Douglas P
2017-11-14
To compare the shrinkage of denture bases fabricated by three methods: CAD/CAM, compression molding, and injection molding. The effect of arch form and palate depth was also tested. Nine titanium casts, representing combinations of tapered, ovoid, and square arch forms and shallow, medium, and deep palate depths, were fabricated using electron beam melting (EBM) technology. For each base fabrication method, three poly(vinyl siloxane) impressions were made from each cast, 27 dentures for each method. Compression-molded dentures were fabricated using Lucitone 199 poly methyl methacrylate (PMMA), and injection molded dentures with Ivobase's Hybrid Pink PMMA. For CAD/CAM, denture bases were designed and milled by Avadent using their Light PMMA. To quantify the space between the denture and the master cast, silicone duplicating material was placed in the intaglio of the dentures, the titanium master cast was seated under pressure, and the silicone was then trimmed and recovered. Three silicone measurements per denture were recorded, for a total of 243 measurements. Each silicone measurement was weighed and adjusted to the surface area of the respective arch, giving an average and standard deviation for each denture. Comparison of manufacturing methods showed a statistically significant difference (p = 0.0001). Using a ratio of the means, compression molding had on average 41% to 47% more space than injection molding and CAD/CAM. Comparison of arch/palate forms showed a statistically significant difference (p = 0.023), with shallow palate forms having more space with compression molding. The ovoid shallow form showed CAD/CAM and compression molding had more space than injection molding. Overall, injection molding and CAD/CAM fabrication methods produced equally well-fitting dentures, with both having a better fit than compression molding. Shallow palates appear to be more affected by shrinkage than medium or deep palates. Shallow ovoid arch forms appear to benefit from the use of injection molding compared to CAD/CAM and compression molding. © 2017 by the American College of Prosthodontists.
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Effects of process parameters in plastic, metal, and ceramic injection molding processes
NASA Astrophysics Data System (ADS)
Lee, Shi W.; Ahn, Seokyoung; Whang, Chul Jin; Park, Seong Jin; Atre, Sundar V.; Kim, Jookwon; German, Randall M.
2011-09-01
Plastic injection molding has been widely used in the past and is a dominant forming approach today. As the customer demands require materials with better engineering properties that were not feasible with polymers, powder injection molding with metal and ceramic powders has received considerable attention in recent decades. To better understand the differences in the plastic injection molding, metal injection molding, and ceramic injection molding, the effects of the core process parameters on the process performances has been studied using the state-of-the-art computer-aided engineering (CAE) design tool, PIMSolver® The design of experiments has been conducted using the Taguchi method to obtain the relative contributions of various process parameters onto the successful operations.
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Low Cost Injection Mold Creation via Hybrid Additive and Conventional Manufacturing
DOE Office of Scientific and Technical Information (OSTI.GOV)
Dehoff, Ryan R.; Watkins, Thomas R.; List, III, Frederick Alyious
2015-12-01
The purpose of the proposed project between Cummins and ORNL is to significantly reduce the cost of the tooling (machining and materials) required to create injection molds to make plastic components. Presently, the high cost of this tooling forces the design decision to make cast aluminum parts because Cummins typical production volumes are too low to allow injection molded plastic parts to be cost effective with the amortized cost of the injection molding tooling. In addition to reducing the weight of components, polymer injection molding allows the opportunity for the alternative cooling methods, via nitrogen gas. Nitrogen gas cooling offersmore » an environmentally and economically attractive cooling option, if the mold can be manufactured economically. In this project, a current injection molding design was optimized for cooling using nitrogen gas. The various components of the injection mold tooling were fabricated using the Renishaw powder bed laser additive manufacturing technology. Subsequent machining was performed on the as deposited components to form a working assembly. The injection mold is scheduled to be tested in a projection setting at a commercial vendor selected by Cummins.« less
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Improved silicon carbide for advanced heat engines. I - Process development for injection molding
NASA Technical Reports Server (NTRS)
Whalen, Thomas J.; Trela, Walter
1989-01-01
Alternate processing methods have been investigated as a means of improving the mechanical properties of injection-molded SiC. Various mixing processes (dry, high-sheer, and fluid) were evaluated along with the morphology and particle size of the starting beta-SiC powder. Statistically-designed experiments were used to determine significant effects and interactions of variables in the mixing, injection molding, and binder removal process steps. Improvements in mechanical strength can be correlated with the reduction in flaw size observed in the injection molded green bodies obtained with improved processing methods.
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Chung, Philip; Heller, J Alex; Etemadi, Mozziyar; Ottoson, Paige E; Liu, Jonathan A; Rand, Larry; Roy, Shuvo
2014-06-27
Biologically inert elastomers such as silicone are favorable materials for medical device fabrication, but forming and curing these elastomers using traditional liquid injection molding processes can be an expensive process due to tooling and equipment costs. As a result, it has traditionally been impractical to use liquid injection molding for low-cost, rapid prototyping applications. We have devised a method for rapid and low-cost production of liquid elastomer injection molded devices that utilizes fused deposition modeling 3D printers for mold design and a modified desiccator as an injection system. Low costs and rapid turnaround time in this technique lower the barrier to iteratively designing and prototyping complex elastomer devices. Furthermore, CAD models developed in this process can be later adapted for metal mold tooling design, enabling an easy transition to a traditional injection molding process. We have used this technique to manufacture intravaginal probes involving complex geometries, as well as overmolding over metal parts, using tools commonly available within an academic research laboratory. However, this technique can be easily adapted to create liquid injection molded devices for many other applications.
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Dimensional Precision Research of Wax Molding Rapid Prototyping based on Droplet Injection
NASA Astrophysics Data System (ADS)
Mingji, Huang; Geng, Wu; yan, Shan
2017-11-01
The traditional casting process is complex, the mold is essential products, mold quality directly affect the quality of the product. With the method of rapid prototyping 3D printing to produce mold prototype. The utility wax model has the advantages of high speed, low cost and complex structure. Using the orthogonal experiment as the main method, analysis each factors of size precision. The purpose is to obtain the optimal process parameters, to improve the dimensional accuracy of production based on droplet injection molding.
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Static Mixer for Heat Transfer Enhancement for Mold Cooling Application
NASA Astrophysics Data System (ADS)
Becerra, Rodolfo; Barbosa, Raul; Lee, Kye-Hwan; Park, Younggil
Injection molding is the process by which a material is melted in a barrel and then it is injected through a nozzle in the mold cavity. When it cools down, the material solidifies into the shape of the cavity. Typical injection mold has cooling channels to maintain constant mold temperature during injection molding process. Even and constant temperature throughout the mold are very critical for a part quality and productivity. Conformal cooling improves the quality and productivity of injection molding process through the implementation of cooling channels that ``conform'' to the shape of the molded part. Recent years, the use of conformal cooling increases with advance of 3D printing technology such as Selective Laser Melting (SLM). Although it maximizes cooling, material and dimension limitations make SLM methods highly expensive. An alternative is the addition of static mixers in the molds with integrated cooling channels. A static mixer is a motionless mixing device that enhances heat transfer by producing improved flow mixing in the pipeline. In this study, the performance of the cooling channels will be evaluated with and without static mixers, by measuring temperature, pressure drop, and flow rate. The following question is addressed: Can a static mixer effectively enhance heat transfer for mold cooling application processes? This will provide insight on the development of design methods and guidelines that can be used to increase cooling efficiency at a lower cost.
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Intelligent methods for the process parameter determination of plastic injection molding
NASA Astrophysics Data System (ADS)
Gao, Huang; Zhang, Yun; Zhou, Xundao; Li, Dequn
2018-03-01
Injection molding is one of the most widely used material processing methods in producing plastic products with complex geometries and high precision. The determination of process parameters is important in obtaining qualified products and maintaining product quality. This article reviews the recent studies and developments of the intelligent methods applied in the process parameter determination of injection molding. These intelligent methods are classified into three categories: Case-based reasoning methods, expert system- based methods, and data fitting and optimization methods. A framework of process parameter determination is proposed after comprehensive discussions. Finally, the conclusions and future research topics are discussed.
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Chung, Philip; Heller, J. Alex; Etemadi, Mozziyar; Ottoson, Paige E.; Liu, Jonathan A.; Rand, Larry; Roy, Shuvo
2014-01-01
Biologically inert elastomers such as silicone are favorable materials for medical device fabrication, but forming and curing these elastomers using traditional liquid injection molding processes can be an expensive process due to tooling and equipment costs. As a result, it has traditionally been impractical to use liquid injection molding for low-cost, rapid prototyping applications. We have devised a method for rapid and low-cost production of liquid elastomer injection molded devices that utilizes fused deposition modeling 3D printers for mold design and a modified desiccator as an injection system. Low costs and rapid turnaround time in this technique lower the barrier to iteratively designing and prototyping complex elastomer devices. Furthermore, CAD models developed in this process can be later adapted for metal mold tooling design, enabling an easy transition to a traditional injection molding process. We have used this technique to manufacture intravaginal probes involving complex geometries, as well as overmolding over metal parts, using tools commonly available within an academic research laboratory. However, this technique can be easily adapted to create liquid injection molded devices for many other applications. PMID:24998993
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Digital Twin concept for smart injection molding
NASA Astrophysics Data System (ADS)
Liau, Y.; Lee, H.; Ryu, K.
2018-03-01
Injection molding industry has evolved over decades and became the most common method to manufacture plastic parts. Monitoring and improvement in the injection molding industry are usually performed separately in each stage, i.e. mold design, mold making and injection molding process. However, in order to make a breakthrough and survive in the industrial revolution, all the stages in injection molding need to be linked and communicated with each other. Any changes in one stage will cause a certain effect in other stage because there is a correlation between each other. Hence, the simulation should not only based on the input of historical data, but it also needs to include the current condition of equipment and prediction of future events in other stages to make the responsive decision. This can be achieved by implementing the concept of Digital Twin that models the entire process as a virtual model and enables bidirectional control with the physical process. This paper presented types of data and technology required to build the Digital Twin for the injection molding industry. The concept includes Digital Twin of each stage and integration of these Digital Twin model as a thoroughgoing model of the injection molding industry.
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Micro Dot Patterning on the Light Guide Panel Using Powder Blasting
Jang, Ho Su; Cho, Myeong Woo; Park, Dong Sam
2008-01-01
This study is to develop a micromachining technology for a light guide panel(LGP) mold, whereby micro dot patterns are formed on a LGP surface by a single injection process instead of existing screen printing processes. The micro powder blasting technique is applied to form micro dot patterns on the LGP mold surface. The optimal conditions for masking, laminating, exposure, and developing processes to form the micro dot patterns are first experimentally investigated. A LGP mold with masked micro patterns is then machined using the micro powder blasting method and the machinability of the micro dot patterns is verified. A prototype LGP is test- injected using the developed LGP mold and a shape analysis of the patterns and performance testing of the injected LGP are carried out. As an additional approach, matte finishing, a special surface treatment method, is applied to the mold surface to improve the light diffusion characteristics, uniformity and brightness of the LGP. The results of this study show that the applied powder blasting method can be successfully used to manufacture LGPs with micro patterns by just single injection using the developed mold and thereby replace existing screen printing methods. PMID:27879740
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NASA Astrophysics Data System (ADS)
Suharno, Bambang; Suharno, Lingga Pradinda; Saputro, Hantoro Restucondro; Irawan, Bambang; Prasetyadi, Tjokro; Ferdian, Deni; Supriyadi, Sugeng
2018-02-01
Surface roughness and microstructure play important role on orthodontic bracket quality. Therefore, orthodontic brackets need to have smooth surface roughness to reduce the friction and bacterial adhesion. Microstructure of orthodontic brackets also determine the mechanical properties and corrosion resistance. There are two methods to produce orthodontic bracket, investment casting and metal injection molding. The purpose of this study is to observe the surface roughness and microstructure of orthodontic bracket which were made from two different fabrication methods. To produce orthodontic bracket with metal injection molding method, 17-4 PH stainless steel feedstock was injected to the orthodontic bracket mold using injection molding machine. After injection, the binder was eliminated with solvent and thermal debinding. Solvent debinding process was conducted with hexane at 50 °C on magnetic stirrer for 1.5 hours. Thermal debinding process was conducted at 510 °C with 0.5 °C/min heat rate and 120 min holding time. Hereafter, sintering process were performed with vacuum tube furnace at 1360 °C with heat rate 5 °C/min and 90 min holding time in low vacuum atmosphere. To produce orthodontic bracket with investment casting method, the wax was injected into the mold then the wax pattern was arranged into the tree form. The tree form was then dipped into ceramic slurry and allowed to harden, the ceramic slurry has a thickness in the region of 10 mm. The ceramic mold was then heated at a temperature of over than 1100°C to strengthen the ceramic mold and to remove the remaining wax. After that, the molten 17-4 PH stainless steel was poured into the ceramic mold at a temperature of over 1600°C. The natural cooling process was carried out at temperature of 25°C, after which the ceramic mold was broken away. Then, the orthodontic bracket was cut from the tree form. The results show that the orthodontic bracket which were made with investment casting fabrication method have low porosity, high density, and there is no indication of secondary phase on the microstructure. However, it has rough brackets surface. Whereas, the production of orthodontic brackets using metal injection molding method resulted in better surface roughness. But, it has relatively high porosity, presence of another phase on the microstructure, and low density.
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Optimization of injection molding process parameters for a plastic cell phone housing component
NASA Astrophysics Data System (ADS)
Rajalingam, Sokkalingam; Vasant, Pandian; Khe, Cheng Seong; Merican, Zulkifli; Oo, Zeya
2016-11-01
To produce thin-walled plastic items, injection molding process is one of the most widely used application tools. However, to set optimal process parameters is difficult as it may cause to produce faulty items on injected mold like shrinkage. This study aims at to determine such an optimum injection molding process parameters which can reduce the fault of shrinkage on a plastic cell phone cover items. Currently used setting of machines process produced shrinkage and mis-specified length and with dimensions below the limit. Thus, for identification of optimum process parameters, maintaining closer targeted length and width setting magnitudes with minimal variations, more experiments are needed. The mold temperature, injection pressure and screw rotation speed are used as process parameters in this research. For optimal molding process parameters the Response Surface Methods (RSM) is applied. The major contributing factors influencing the responses were identified from analysis of variance (ANOVA) technique. Through verification runs it was found that the shrinkage defect can be minimized with the optimal setting found by RSM.
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Effect of processing method on the mechanical and thermal of Silvergrass/HDPE composites
NASA Astrophysics Data System (ADS)
Liu, Bing; Jin, Yueqiang; Wang, Shuying
2017-05-01
This paper investigates the effect of compression and injection molding methods on properties of Silvergrass-HDPE (High Density Polyethylene) composites, with respect to mechanical behaviors. Maleated polyethylene (MAPE) was added in the composite and improved the mechanical property of the composite. The research founds MAPE can improve the mechanical property because it improved the interfacial compatibility as a coupling agent. When added a content of 8% of MAPE, Silvergrass-HDPE composites made from compression molding shows a better mechanical performance in tensile strength and flexural strength than that made from injection molding, with increasing Silvergrass fiber content from 30% to 50%. However, the WPCs (wood plastics composites) made from injection molding had a lower degree of crystallinity with or without MAPE treatment.
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Replication fidelity improvement of PMMA microlens array based on weight evaluation and optimization
NASA Astrophysics Data System (ADS)
Jiang, Bing-yan; Shen, Long-jiang; Peng, Hua-jiang; Yin, Xiang-lin
2007-12-01
High replication fidelity is a prerequisite of high quality plastic microlens array in injection molding. But, there's not an economical and practical method to evaluate and improve the replication fidelity until now. Based on part weight evaluation and optimization, this paper presents a new method of replication fidelity improvement. Firstly, a simplified analysis model of PMMA micro columns arrays (5×16) with 200μm diameter was set up. And then, Flow (3D) module of Moldflow MPI6.0 based on Navier-Stokes equations was used to calculate the weight of the micro columns arrays in injection molding. The effects of processing parameters (melt temperature, mold temperature, injection time, packing pressure and packing time) on the part weight were investigated in the simulations. The simulation results showed that the mold temperature and the injection time have important effects on the filling of micro columns; the optimal mold temperature and injection time for better replication fidelity could be determined by the curves of mold temperature vs part weight and injection time vs part weight. At last, the effects of processing parameters on part weight of micro columns array were studied experimentally. The experimental results showed that the increase of melt temperature and mold temperature can make the packing pressure transfer to micro cavity more effectively through runner system, and increase the part weight. From the observation results of the image measuring apparatus, it was discovered that the higher the part weight, the better the filling of the microstructures. In conclusion, part weight can be used to evaluate the replication fidelity of micro-feature structured parts primarily; which is an economical and practical method to improve the replication fidelity of microlens arrays based on weight evaluation and optimization.
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Residual stresses in injection molded shape memory polymer parts
NASA Astrophysics Data System (ADS)
Katmer, Sukran; Esen, Huseyin; Karatas, Cetin
2016-03-01
Shape memory polymers (SMPs) are materials which have shape memory effect (SME). SME is a property which has the ability to change shape when induced by a stimulator such as temperature, moisture, pH, electric current, magnetic field, light, etc. A process, known as programming, is applied to SMP parts in order to alter them from their permanent shape to their temporary shape. In this study we investigated effects of injection molding and programming processes on residual stresses in molded thermoplastic polyurethane shape memory polymer, experimentally. The residual stresses were measured by layer removal method. The study shows that injection molding and programming process conditions have significantly influence on residual stresses in molded shape memory polyurethane parts.
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Micro Machining of Injection Mold Inserts for Fluidic Channel of Polymeric Biochips
Jung, Woo-Chul; Heo, Young-Moo; Yoon, Gil-Sang; Shin, Kwang-Ho; Chang, Sung-Ho; Kim, Gun-Hee; Cho, Myeong-Woo
2007-01-01
Recently, the polymeric micro-fluidic biochip, often called LOC (lab-on-a-chip), has been focused as a cheap, rapid and simplified method to replace the existing biochemical laboratory works. It becomes possible to form miniaturized lab functionalities on a chip with the development of MEMS technologies. The micro-fluidic chips contain many micro-channels for the flow of sample and reagents, mixing, and detection tasks. Typical substrate materials for the chip are glass and polymers. Typical techniques for microfluidic chip fabrication are utilizing various micro pattern forming methods, such as wet-etching, micro-contact printing, and hot-embossing, micro injection molding, LIGA, and micro powder blasting processes, etc. In this study, to establish the basis of the micro pattern fabrication and mass production of polymeric micro-fluidic chips using injection molding process, micro machining method was applied to form micro-channels on the LOC molds. In the research, a series of machining experiments using micro end-mills were performed to determine optimum machining conditions to improve surface roughness and shape accuracy of designed simplified micro-channels. Obtained conditions were used to machine required mold inserts for micro-channels using micro end-mills. Test injection processes using machined molds and COC polymer were performed, and then the results were investigated.
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Process influences and correction possibilities for high precision injection molded freeform optics
NASA Astrophysics Data System (ADS)
Dick, Lars; Risse, Stefan; Tünnermann, Andreas
2016-08-01
Modern injection molding processes offer a cost-efficient method for manufacturing high precision plastic optics for high volume applications. Besides form deviation of molded freeform optics, internal material stress is a relevant influencing factor for the functionality of a freeform optics in an optical system. This paper illustrates dominant influence parameters of an injection molding process relating to form deviation and internal material stress based on a freeform demonstrator geometry. Furthermore, a deterministic and efficient way for 3D mold correcting of systematic, asymmetrical shrinkage errors is shown to reach micrometer range shape accuracy at diameters up to 40 mm. In a second case, a stress-optimized parameter combination using unusual molding conditions was 3D corrected to reach high precision and low stress freeform polymer optics.
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Parameter Optimization Of Natural Hydroxyapatite/SS316l Via Metal Injection Molding (MIM)
NASA Astrophysics Data System (ADS)
Mustafa, N.; Ibrahim1, M. H. I.; Amin, A. M.; Asmawi, R.
2017-01-01
Metal injection molding (MIM) are well known as a worldwide application of powder injection molding (PIM) where as applied the shaping concept and the beneficial of plastic injection molding but develops the applications to various high performance metals and alloys, plus metal matrix composites and ceramics. This study investigates the strength of green part by using stainless steel 316L/ Natural hydroxyapatite composite as a feedstock. Stainless steel 316L (SS316L) was mixed with Natural hydroxyapatite (NHAP) by adding 40 wt. % Low Density Polyethylene and 60 %wt. Palm Stearin as a binder system at 63 wt. % powder loading consist of 90 % wt. of SS316 L and 10 wt. % NHAP prepared thru critical powder volume percentage (CPVC). Taguchi method was functional as a tool in determining the optimum green strength for Metal Injection Molding (MIM) parameters. The green strength was optimized with 4 significant injection parameter such as Injection temperature (A), Mold temperature (B), Pressure (C) and Speed (D) were selected throughout screening process. An orthogonal array of L9 (3)4 was conducted. The optimum injection parameters for highest green strength were established at A1, B2, C0 and D1 and where as calculated based on Signal to Noise Ratio.
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Micro-optical fabrication by ultraprecision diamond machining and precision molding
NASA Astrophysics Data System (ADS)
Li, Hui; Li, Likai; Naples, Neil J.; Roblee, Jeffrey W.; Yi, Allen Y.
2017-06-01
Ultraprecision diamond machining and high volume molding for affordable high precision high performance optical elements are becoming a viable process in optical industry for low cost high quality microoptical component manufacturing. In this process, first high precision microoptical molds are fabricated using ultraprecision single point diamond machining followed by high volume production methods such as compression or injection molding. In the last two decades, there have been steady improvements in ultraprecision machine design and performance, particularly with the introduction of both slow tool and fast tool servo. Today optical molds, including freeform surfaces and microlens arrays, are routinely diamond machined to final finish without post machining polishing. For consumers, compression molding or injection molding provide efficient and high quality optics at extremely low cost. In this paper, first ultraprecision machine design and machining processes such as slow tool and fast too servo are described then both compression molding and injection molding of polymer optics are discussed. To implement precision optical manufacturing by molding, numerical modeling can be included in the future as a critical part of the manufacturing process to ensure high product quality.
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[Determination of acrylonitrile in injection molding process: data analysis and recommendations].
Zhong, X P; Chen, Z R; Zhu, Z L
2017-07-20
Objective: To investigate whether the identification of acrylonitrile, an occupational hazard factor for the industry of injection molding and plastic products, reported in literature is reasonable, and to put forward some recommendations. Methods: Professional articles published from 1990 to 2016 were searched, and an analysis was performed for the data on the determination of acrylonitrile in the industry of injection molding and plastic products from 2003 to 2016 in Longhua Center for Disease Control and Prevention of Shenzhen. Results: According to the literature, the detection rate of acrylonitrile was 10.7%, and the detection results did not exceed the limit. Conclusion: At present, acrylonitrile may not be used as a routine test item for the industry of injection molding and plastic products, in order to save manpower and material resources.
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Dimensional Changes of Acrylic Resin Denture Bases: Conventional Versus Injection-Molding Technique
Gharechahi, Jafar; Asadzadeh, Nafiseh; Shahabian, Foad; Gharechahi, Maryam
2014-01-01
Objective: Acrylic resin denture bases undergo dimensional changes during polymerization. Injection molding techniques are reported to reduce these changes and thereby improve physical properties of denture bases. The aim of this study was to compare dimensional changes of specimens processed by conventional and injection-molding techniques. Materials and Methods: SR-Ivocap Triplex Hot resin was used for conventional pressure-packed and SR-Ivocap High Impact was used for injection-molding techniques. After processing, all the specimens were stored in distilled water at room temperature until measured. For dimensional accuracy evaluation, measurements were recorded at 24-hour, 48-hour and 12-day intervals using a digital caliper with an accuracy of 0.01 mm. Statistical analysis was carried out by SPSS (SPSS Inc., Chicago, IL, USA) using t-test and repeated-measures ANOVA. Statistical significance was defined at P<0.05. Results: After each water storage period, the acrylic specimens produced by injection exhibited less dimensional changes compared to those produced by the conventional technique. Curing shrinkage was compensated by water sorption with an increase in water storage time decreasing dimensional changes. Conclusion: Within the limitations of this study, dimensional changes of acrylic resin specimens were influenced by the molding technique used and SR-Ivocap injection procedure exhibited higher dimensional accuracy compared to conventional molding. PMID:25584050
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Retention of denture bases fabricated by three different processing techniques – An in vivo study
Chalapathi Kumar, V. H.; Surapaneni, Hemchand; Ravikiran, V.; Chandra, B. Sarat; Balusu, Srilatha; Reddy, V. Naveen
2016-01-01
Aim: Distortion due to Polymerization shrinkage compromises the retention. To evaluate the amount of retention of denture bases fabricated by conventional, anchorized, and injection molding polymerization techniques. Materials and Methods: Ten completely edentulous patients were selected, impressions were made, and master cast obtained was duplicated to fabricate denture bases by three polymerization techniques. Loop was attached to the finished denture bases to estimate the force required to dislodge them by retention apparatus. Readings were subjected to nonparametric Friedman two-way analysis of variance followed by Bonferroni correction methods and Wilcoxon matched-pairs signed-ranks test. Results: Denture bases fabricated by injection molding (3740 g), anchorized techniques (2913 g) recorded greater retention values than conventional technique (2468 g). Significant difference was seen between these techniques. Conclusions: Denture bases obtained by injection molding polymerization technique exhibited maximum retention, followed by anchorized technique, and least retention was seen in conventional molding technique. PMID:27382542
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An investigation into the injection molding of PMR-15 polyimide
NASA Technical Reports Server (NTRS)
Colaluca, M. A.
1984-01-01
The chemorheological behavior of the PRM-15 molding compounds were characterized, the range of suitable processing parameters for injection molding in a reciprocating screw injection molding machine was determined, and the effects of the injection molding processing parameters on the mechanical properties of molded PMR-15 parts were studied. The apparatus and procedures for measuring viscosity and for determining the physical response of the material during heating are described. Results show that capillary rheometry can be effectively used with thermosets if the equipment is designed to overcome some of the inherent problems of these materials. A uniform temperature was provided in the barrel by using a circulating hot oil system. Standard capillary rheometry methods can provide the dependence of thermoset apparent viscosity on shear rate, temperature, and time. Process conditions resulting in complete imidization should be carefully defined. Specification of controlled oven temperature is inadequate and can result in incomplete imidization. For completely imidized PMR-15 heat at 15 C/min melt flow without gas evolution occurs in the temperature range of 325 C to 400 C.
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Simmons, Blake [San Francisco, CA; Domeier, Linda [Danville, CA; Woo, Noble [San Gabriet, CA; Shepodd, Timothy [Livermore, CA; Renzi, Ronald F [Tracy, CA
2008-04-01
Injection molding is used to form microfluidic devices with integrated functional components. One or more functional components are placed in a mold cavity which is then closed. Molten thermoplastic resin is injected into the mold and then cooled, thereby forming a solid substrate including the functional component(s). The solid substrate including the functional component(s) is then bonded to a second substrate which may include microchannels or other features.
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Methods for integrating a functional component into a microfluidic device
Simmons, Blake; Domeier, Linda; Woo, Noble; Shepodd, Timothy; Renzi, Ronald F.
2014-08-19
Injection molding is used to form microfluidic devices with integrated functional components. One or more functional components are placed in a mold cavity, which is then closed. Molten thermoplastic resin is injected into the mold and then cooled, thereby forming a solid substrate including the functional component(s). The solid substrate including the functional component(s) is then bonded to a second substrate, which may include microchannels or other features.
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Fabrication of robust tooling for mass production of polymeric microfluidic devices
NASA Astrophysics Data System (ADS)
Fu, G.; Tor, S. B.; Loh, N. H.; Hardt, D. E.
2010-08-01
Polymer microfluidic devices are gaining popularity for bio-applications. In both commonly used methods for the fabrication of polymer microfluidic devices, i.e. injection molding and hot-embossing, the quality of a mold insert is of high importance. Micro powder injection molding (μPIM) provides a suitable option for metal mold insert fabrication. In this paper, two mold inserts with micro-features of different patterns and sizes were produced using 316L stainless steel powder and an in-house binder system. The mold inserts were successfully used to produce cyclic olefin copolymer (COC, trade name TOPAS) micromixer plates with micro-channels of widths 100 µm and 50 µm. Compared with CNC-machined hot work steel mold inserts, the quality of the micro-channels is better as far as geometrical quality and dimensional tolerance are concerned. However, surface finish and flatness of the μPIM mold inserts are inferior to those of CNC-machined mold inserts.
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Mathematical modeling of the in-mold coating process for injection-molded thermoplastic parts
NASA Astrophysics Data System (ADS)
Chen, Xu
In-Mold Coating (IMC) has been successfully used for many years for exterior body panels made from compression molded Sheet Molding Compound (SMC). The coating material is a single component reactive fluid, designed to improve the surface quality of SMC moldings in terms of functional and cosmetic properties. When injected onto a cured SMC part, IMC cures and bonds to provide a pain-like surface. Because of its distinct advantages, IMC is being considered for application to injection molded thermoplastic parts. For a successful in mold coating operation, there are two key issues related to the flow of the coating. First, the injection nozzle should be located such that the thermoplastic substrate is totally covered and the potential for air trapping is minimized. The selected location should be cosmetically acceptable since it most likely will leave a mark on the coated surface. The nozzle location also needs to be accessible for easy of maintenance. Secondly, the hydraulic force generated by the coating injection pressure should not exceed the available clamping tonnage. If the clamping force is exceeded, coating leakage will occur. In this study, mathematical models for IMC flow on the compressible thermoplastic substrate have been developed. Finite Difference Method (FDM) is first used to solve the 1 dimensional (1D) IMC flow problem. In order to investigate the application of Control Volume based Finite Element Method (CV/FEM) to more complicated two dimensional IMC flow, that method is first evaluated by solving the 1D IMC flow problem. An analytical solution, which can be obtained when a linear relationship between the coating thickness and coating injection pressure is assumed, is used to verify the numerical results. The mathematical models for the 2 dimensional (2D) IMC flow are based on the generalized Hele-Shaw approximation. It has been found experimentally that the power law viscosity model adequately predicts the rheological behavior of the coating. The compressibility of the substrate is modeled by the 2-domain Tait PVT equation. CV/FEM is used to solve the discretized governing equations. A computer code has been developed to predict the fill pattern of the coating and the injection pressure. A number of experiments have been conducted to verify the numerical predictions of the computer code. It has been found both numerically and experimentally that the substrate thickness plays a significant role on the IMC fill pattern.
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FPGA-based multiprocessor system for injection molding control.
Muñoz-Barron, Benigno; Morales-Velazquez, Luis; Romero-Troncoso, Rene J; Rodriguez-Donate, Carlos; Trejo-Hernandez, Miguel; Benitez-Rangel, Juan P; Osornio-Rios, Roque A
2012-10-18
The plastic industry is a very important manufacturing sector and injection molding is a widely used forming method in that industry. The contribution of this work is the development of a strategy to retrofit control of an injection molding machine based on an embedded system microprocessors sensor network on a field programmable gate array (FPGA) device. Six types of embedded processors are included in the system: a smart-sensor processor, a micro fuzzy logic controller, a programmable logic controller, a system manager, an IO processor and a communication processor. Temperature, pressure and position are controlled by the proposed system and experimentation results show its feasibility and robustness. As validation of the present work, a particular sample was successfully injected.
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NASA Astrophysics Data System (ADS)
He, Liping; Lu, Gang; Chen, Dachuan; Li, Wenjun; Lu, Chunsheng
2017-07-01
This paper investigates the three-dimensional (3D) injection molding flow of short fiber-reinforced polymer composites using a smoothed particle hydrodynamics (SPH) simulation method. The polymer melt was modeled as a power law fluid and the fibers were considered as rigid cylindrical bodies. The filling details and fiber orientation in the injection-molding process were studied. The results indicated that the SPH method could effectively predict the order of filling, fiber accumulation, and heterogeneous distribution of fibers. The SPH simulation also showed that fibers were mainly aligned to the flow direction in the skin layer and inclined to the flow direction in the core layer. Additionally, the fiber-orientation state in the simulation was quantitatively analyzed and found to be consistent with the results calculated by conventional tensor methods.
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Molten metal injector system and method
Meyer, Thomas N.; Kinosz, Michael J.; Bigler, Nicolas; Arnaud, Guy
2003-04-01
Disclosed is a molten metal injector system including a holder furnace, a casting mold supported above the holder furnace, and a molten metal injector supported from a bottom side of the mold. The holder furnace contains a supply of molten metal having a metal oxide film surface. The bottom side of the mold faces the holder furnace. The mold defines a mold cavity for receiving the molten metal from the holder furnace. The injector projects into the holder furnace and is in fluid communication with the mold cavity. The injector includes a piston positioned within a piston cavity defined by a cylinder for pumping the molten metal upward from the holder furnace and injecting the molten metal into the mold cavity under pressure. The piston and cylinder are at least partially submerged in the molten metal when the holder furnace contains the molten metal. The cylinder further includes a molten metal intake for receiving the molten metal into the piston cavity. The molten metal intake is located below the metal oxide film surface of the molten metal when the holder furnace contains the molten metal. A method of injecting molten metal into a mold cavity of a casting mold is also disclosed.
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Thermoplastics for aircraft interiors
NASA Technical Reports Server (NTRS)
Silverman, B.
1978-01-01
The goal for this contract is the development of processes and techniques for molding thermally stable, fire retardant, low smoke emitting polymeric materials. Outlined in this presentation are: (1) the typical molding types; (2) a program schedule; (3) physical properties of molding types with the test methods to be used; (4) general properties of injection molding materials; and (5) preliminary materials selection.
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Forehead Augmentation with a Methyl Methacrylate Onlay Implant Using an Injection-Molding Technique
Park, Dong Kwon; Song, Ingook; Lee, Jin Hyo
2013-01-01
Background The forehead, which occupies about one third of the face, is one of the major determinants of a feminine or masculine look. Various methods have been used for the augmentation of the forehead using autologous fat grafts or alloplastic materials. Methylmethacrylate (MMA) is the most appropriate material for augmentation of the forehead, and we have used an injection-molding technique with MMA to achieve satisfactory results. Methods Under local anesthesia with intravenous (IV) sedation, an incision was made on the scalp and a meticulous and delicate subperiosteal dissection was then performed. MMA monomers and polymers were mixed, the dough was injected into the space created, and manual molding was performed along with direct inspection. This surgery was indicated for patients who wanted to correct an unattractive appearance by forehead augmentation. Every patient in this study visited our clinics 3 months after surgery to evaluate the results. We judged the postoperative results in terms of re-operation rates caused by the dissatisfaction of the patients and complications. Results During a 13-year period, 516 patients underwent forehead augmentation with MMA. With the injection-molding technique, the inner surface of the MMA implant is positioned close to the underlying frontal bone, which minimizes the gap between the implant and bone. The borders of the implant should be tapered sufficiently until no longer palpable or visible. Only 28 patients (5.4%) underwent a re-operation due to an undesirable postoperative appearance. Conclusions The injection-molding technique using MMA is a simple, safe, and ideal method for the augmentation of the forehead. PMID:24086816
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Molding of strength testing samples using modern PDCPD material for purpose of automotive industry
NASA Astrophysics Data System (ADS)
Grabowski, L.; Baier, A.; Sobek, M.
2017-08-01
The casting of metal materials is widely known but the molding of composite polymer materials is not well-known method still. The initial choice of method for producing composite bodies was the method of casting of PDCPD material. For purpose of performing casting of polymer composite material, a special mold was made. Firstly, the 3D printed, using PLA material, mold was used. After several attempts of casting PDCPD many problems were encountered. The second step was to use mold milled from a firm and dense isocyanate foam. After several attempts research shown that this solution is more resistant to high-temperature peak, but this material is too fragile to use it several times. This solution also prevents mold from using external heating, which can be necessary for performing correct molding process. The last process was to use the aluminum mold, which is dedicated to PDCPD polymer composite, because of low adhesiveness. This solution leads to perform correct PDCPD polymer composite material injection. After performing casting operation every PDCPD testing samples were tested. These results were compared together. The result of performed work was to archive correct properties of injection of composite material. Research and results were described in detail in this paper.
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FPGA-Based Multiprocessor System for Injection Molding Control
Muñoz-Barron, Benigno; Morales-Velazquez, Luis; Romero-Troncoso, Rene J.; Rodriguez-Donate, Carlos; Trejo-Hernandez, Miguel; Benitez-Rangel, Juan P.; Osornio-Rios, Roque A.
2012-01-01
The plastic industry is a very important manufacturing sector and injection molding is a widely used forming method in that industry. The contribution of this work is the development of a strategy to retrofit control of an injection molding machine based on an embedded system microprocessors sensor network on a field programmable gate array (FPGA) device. Six types of embedded processors are included in the system: a smart-sensor processor, a micro fuzzy logic controller, a programmable logic controller, a system manager, an IO processor and a communication processor. Temperature, pressure and position are controlled by the proposed system and experimentation results show its feasibility and robustness. As validation of the present work, a particular sample was successfully injected. PMID:23202036
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Evaluation of Three Different Processing Techniques in the Fabrication of Complete Dentures
Chintalacheruvu, Vamsi Krishna; Balraj, Rajasekaran Uttukuli; Putchala, Lavanya Sireesha; Pachalla, Sreelekha
2017-01-01
Aims and Objectives: The objective of the present study is to compare the effectiveness of three different processing techniques and to find out the accuracy of processing techniques through number of occlusal interferences and increase in vertical dimension after denture processing. Materials and Methods: A cross-sectional study was conducted on a sample of 18 patients indicated for complete denture fabrication was selected for the study and they were divided into three subgroups. Three processing techniques, compression molding and injection molding using prepolymerized resin and unpolymerized resin, were used to fabricate dentures for each of the groups. After processing, laboratory-remounted dentures were evaluated for number of occlusal interferences in centric and eccentric relations and change in vertical dimension through vertical pin rise in articulator. Data were analyzed using statistical test ANOVA and SPSS software version 19.0 by IBM was used. Results: Data obtained from three groups were subjected to one-way ANOVA test. After ANOVA test, results with significant variations were subjected to post hoc test. Number of occlusal interferences with compression molding technique was reported to be more in both centric and eccentric positions as compared to the two injection molding techniques with statistical significance in centric, protrusive, right lateral nonworking, and left lateral working positions (P < 0.05). Mean vertical pin rise (0.52 mm) was reported to more in compression molding technique as compared to injection molding techniques, which is statistically significant (P < 0.001). Conclusions: Within the limitations of this study, injection molding techniques exhibited less processing errors as compared to compression molding technique with statistical significance. There was no statistically significant difference in processing errors reported within two injection molding systems. PMID:28713763
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NASA Technical Reports Server (NTRS)
Pritchett, Victor E., II (Inventor); Wang, Ten-See (Inventor); Blankson, Isaiah M. (Inventor); Daso, Endwell O. (Inventor); Farr, Rebecca Ann (Inventor); Auslender, Aaron Howard (Inventor); Plotkin, Kenneth J. (Inventor)
2015-01-01
A method and system are provided to weaken shock wave strength at leading edge surfaces of a vehicle in atmospheric flight. One or more flight-related attribute sensed along a vehicle's outer mold line are used to control the injection of a non-heated, non-plasma-producing gas into a local external flowfield of the vehicle from at least one leading-edge surface location along the vehicle's outer mold line. Pressure and/or mass flow rate of the gas so-injected is adjusted in order to cause a Rankine-Hugoniot Jump Condition along the vehicle's outer mold line to be violated.
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Tsai, Kuo-Ming; Wang, He-Yi
2014-08-20
This study focuses on injection molding process window determination for obtaining optimal imaging optical properties, astigmatism, coma, and spherical aberration using plastic lenses. The Taguchi experimental method was first used to identify the optimized combination of parameters and significant factors affecting the imaging optical properties of the lens. Full factorial experiments were then implemented based on the significant factors to build the response surface models. The injection molding process windows for lenses with optimized optical properties were determined based on the surface models, and confirmation experiments were performed to verify their validity. The results indicated that the significant factors affecting the optical properties of lenses are mold temperature, melt temperature, and cooling time. According to experimental data for the significant factors, the oblique ovals for different optical properties on the injection molding process windows based on melt temperature and cooling time can be obtained using the curve fitting approach. The confirmation experiments revealed that the average errors for astigmatism, coma, and spherical aberration are 3.44%, 5.62%, and 5.69%, respectively. The results indicated that the process windows proposed are highly reliable.
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Porous media heat transfer for injection molding
Beer, Neil Reginald
2016-05-31
The cooling of injection molded plastic is targeted. Coolant flows into a porous medium disposed within an injection molding component via a porous medium inlet. The porous medium is thermally coupled to a mold cavity configured to receive injected liquid plastic. The porous medium beneficially allows for an increased rate of heat transfer from the injected liquid plastic to the coolant and provides additional structural support over a hollow cooling well. When the temperature of the injected liquid plastic falls below a solidifying temperature threshold, the molded component is ejected and collected.
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NASA Technical Reports Server (NTRS)
Daso, Endwell O. (Inventor); Pritchett, II, Victor E. (Inventor); Wang, Ten-See (Inventor); Farr, Rebecca Ann (Inventor)
2012-01-01
The upstream flowfield of a vehicle traveling in supersonic or hypersonic atmospheric flight is actively controlled using attribute(s) experienced by the vehicle. Sensed attribute(s) include pressure along the vehicle's outer mold line, temperature along the vehicle's outer mold line, heat flux along the vehicle's outer mold line, and/or local acceleration response of the vehicle. A non-heated, non-plasma-producing gas is injected into an upstream flowfield of the vehicle from at least one surface location along the vehicle's outer mold line. The pressure of the gas so-injected is adjusted based on the attribute(s) so-sensed.
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Precision injection molding of freeform optics
NASA Astrophysics Data System (ADS)
Fang, Fengzhou; Zhang, Nan; Zhang, Xiaodong
2016-08-01
Precision injection molding is the most efficient mass production technology for manufacturing plastic optics. Applications of plastic optics in field of imaging, illumination, and concentration demonstrate a variety of complex surface forms, developing from conventional plano and spherical surfaces to aspheric and freeform surfaces. It requires high optical quality with high form accuracy and lower residual stresses, which challenges both optical tool inserts machining and precision injection molding process. The present paper reviews recent progress in mold tool machining and precision injection molding, with more emphasis on precision injection molding. The challenges and future development trend are also discussed.
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40 CFR Table 9 to Subpart Wwww of... - Initial Compliance With Work Practice Standards
Code of Federal Regulations, 2014 CFR
2014-07-01
... compression/injection molding uncover, unwrap or expose only one charge per mold cycle per compression/injection molding machine. For machines with multiple molds, one charge means sufficient material to fill... cycle per compression/injection molding machine, or prior to the loader, hoppers are closed except when...
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Kobayashi, Masanori; Oka, Masanori
2004-01-01
We have developed a hip hemi-arthroplasty using polyvinyl alcohol-hydrogel (PVA-H) as the treatment for hip joint disorders in which the lesion is limited to the joint surface. In previous studies, we characterized the biocompatibility and the mechanical properties of PVA-H as an arthroplasty material. To fix PVA-H firmly to the bone, we have devised an implant composed of PVA-H and porous titanium fiber mesh (TFM). However, because of poor infiltration of the PVA solution into the pores of the TFM when using the low temperature crystallization method, the strength of the PVA-H-TFM interface was insufficient. Consequently, the infiltration method was improved by adopting high-pressure injection molding. With this improved method, the bonding strength of the interface increased remarkably. However, as this injection molding requires high temperature, various mechanical properties of the PVA-H might change with this treatment in comparison with the previous method. The purpose of this study was to investigate the effect of high temperature treatment on the mechanical properties of PVA-H as artificial articular cartilage, the tensile test and friction test were performed about new PVA-H. The results showed no significant mechanical deterioration of the PVA-H. This certified that the injection-molding method did not induce the change of the mechanical properties of PVA-H and indicated the potential of hemi-arthroplasty using PVA-H by this method in the future.
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Höll, S; Haupt, M; Fischer, U H P
2013-06-20
Optical simulation software based on the ray-tracing method offers easy and fast results in imaging optics. This method can also be applied in other fields of light propagation. For short distance communications, polymer optical fibers (POFs) are gradually gaining importance. This kind of fiber offers a larger core diameter, e.g., the step index POF features a core diameter of 980 μm. Consequently, POFs have a large number of modes (>3 million modes) in the visible range, and ray tracing could be used to simulate the propagation of light. This simulation method is applicable not only for the fiber itself but also for the key components of a complete POF network, e.g., couplers or other key elements of the transmission line. In this paper a demultiplexer designed and developed by means of ray tracing is presented. Compared to the classical optical design, requirements for optimal design differ particularly with regard to minimizing the insertion loss (IL). The basis of the presented key element is a WDM device using a Rowland spectrometer setup. In this approach the input fiber carries multiple wavelengths, which will be divided into multiple output fibers that transmit only one wavelength. To adapt the basic setup to POF, the guidance of light in this element has to be changed fundamentally. Here, a monolithic approach is presented with a blazed grating using an aspheric mirror to minimize most of the aberrations. In the simulations the POF is represented by an area light source, while the grating is analyzed for different orders and the highest possible efficiency. In general, the element should be designed in a way that it can be produced with a mass production technology like injection molding in order to offer a reasonable price. However, designing the elements with regard to injection molding leads to some inherent challenges. The microstructure of an optical grating and the thick-walled 3D molded parts both result in high demands on the injection molding process. This also requires complex machining of the molding tool. Therefore, different experiments are done to optimize the process parameter, find the best molding material, and find a suitable machining method for the molding tool. The paper will describe the development of the demultiplexer by means of ray-tracing simulations step by step. Also, the process steps and the realized solutions for the injection molding are described.
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Injection molding of iPP samples in controlled conditions and resulting morphology
DOE Office of Scientific and Technical Information (OSTI.GOV)
Sessa, Nino, E-mail: ninosessa.ns@gmail.com; De Santis, Felice, E-mail: fedesantis@unisa.it; Pantani, Roberto, E-mail: rpantani@unisa.it
2015-12-17
Injection molded parts are driven down in size and weight especially for electronic applications. In this work, an investigation was carried out on the process of injection molding of thin iPP samples and on the morphology of these parts. Melt flow in the mold cavity was analyzed and described with a mathematical model. Influence of mold temperature and injection pressure was analyzed. Samples orientation was studied using optical microscopy.
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Injection molding ceramics to high green densities
NASA Technical Reports Server (NTRS)
Mangels, J. A.; Williams, R. M.
1983-01-01
The injection molding behavior of a concentrated suspension of Si powder in wax was studied. It was found that the injection molding behavior was a function of the processing techniques used to generate the powder. Dry ball-milled powders had the best molding behavior, while air classified and impact-milled powders demonstrated poorer injection moldability. The relative viscosity of these molding batches was studied as a function of powder properties: distribution shape, surface area, packing density, and particle morphology. The experimental behavior, in all cases, followed existing theories. The relative viscosity of an injection molding composition composed of dry ball-milled powders could be expressed using Farris' relation.
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Design and Checking Analysis of Injection Mold for a Plastic Cup
NASA Astrophysics Data System (ADS)
Li, Xuebing
2018-03-01
A special injection mold was designed for the structural characteristics of a plastic cup part. The mold was simulated by Moldflow software and verified by calculating the stripping force, the pulling force and the clamping force of the mold so that to determine the appropriate injection parameters. It has been proved that the injection mold is effective and practical in the actual producing and can meet the quality requirements during the course of using it, which solved some problems for injection molding of this kind of parts and can provide some reference for the production of other products in the same industry.
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Optimization of Micro Metal Injection Molding By Using Grey Relational Grade
DOE Office of Scientific and Technical Information (OSTI.GOV)
Ibrahim, M. H. I.; Precision Process Research Group, Dept. of Mechanical and Materials Engineering, Faculty of Engineering, Universiti Kebangsaan Malaysia; Muhamad, N.
2011-01-17
Micro metal injection molding ({mu}MIM) which is a variant of MIM process is a promising method towards near net-shape of metallic micro components of complex geometry. In this paper, {mu}MIM is applied to produce 316L stainless steel micro components. Due to highly stringent characteristic of {mu}MIM properties, the study has been emphasized on optimization of process parameter where Taguchi method associated with Grey Relational Analysis (GRA) will be implemented as it represents novel approach towards investigation of multiple performance characteristics. Basic idea of GRA is to find a grey relational grade (GRG) which can be used for the optimization conversionmore » from multi objectives case which are density and strength to a single objective case. After considering the form 'the larger the better', results show that the injection time(D) is the most significant followed by injection pressure(A), holding time(E), mold temperature(C) and injection temperature(B). Analysis of variance (ANOVA) is also employed to strengthen the significant of each parameter involved in this study.« less
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Micro Dot Patterning on the Light Guide Panel Using Powder Blasting.
Jang, Ho Su; Cho, Myeong Woo; Park, Dong Sam
2008-02-08
This study is to develop a micromachining technology for a light guidepanel(LGP) mold, whereby micro dot patterns are formed on a LGP surface by a singleinjection process instead of existing screen printing processes. The micro powder blastingtechnique is applied to form micro dot patterns on the LGP mold surface. The optimalconditions for masking, laminating, exposure, and developing processes to form the microdot patterns are first experimentally investigated. A LGP mold with masked micro patternsis then machined using the micro powder blasting method and the machinability of themicro dot patterns is verified. A prototype LGP is test- injected using the developed LGPmold and a shape analysis of the patterns and performance testing of the injected LGP arecarried out. As an additional approach, matte finishing, a special surface treatment method,is applied to the mold surface to improve the light diffusion characteristics, uniformity andbrightness of the LGP. The results of this study show that the applied powder blastingmethod can be successfully used to manufacture LGPs with micro patterns by just singleinjection using the developed mold and thereby replace existing screen printing methods.
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Forehead augmentation with a methyl methacrylate onlay implant using an injection-molding technique.
Park, Dong Kwon; Song, Ingook; Lee, Jin Hyo; You, Young June
2013-09-01
The forehead, which occupies about one third of the face, is one of the major determinants of a feminine or masculine look. Various methods have been used for the augmentation of the forehead using autologous fat grafts or alloplastic materials. Methylmethacrylate (MMA) is the most appropriate material for augmentation of the forehead, and we have used an injection-molding technique with MMA to achieve satisfactory results. Under local anesthesia with intravenous (IV) sedation, an incision was made on the scalp and a meticulous and delicate subperiosteal dissection was then performed. MMA monomers and polymers were mixed, the dough was injected into the space created, and manual molding was performed along with direct inspection. This surgery was indicated for patients who wanted to correct an unattractive appearance by forehead augmentation. Every patient in this study visited our clinics 3 months after surgery to evaluate the results. We judged the postoperative results in terms of re-operation rates caused by the dissatisfaction of the patients and complications. During a 13-year period, 516 patients underwent forehead augmentation with MMA. With the injection-molding technique, the inner surface of the MMA implant is positioned close to the underlying frontal bone, which minimizes the gap between the implant and bone. The borders of the implant should be tapered sufficiently until no longer palpable or visible. Only 28 patients (5.4%) underwent a re-operation due to an undesirable postoperative appearance. The injection-molding technique using MMA is a simple, safe, and ideal method for the augmentation of the forehead.
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Dimensional change in complete dentures fabricated by injection molding and microwave processing.
Keenan, Phillip L J; Radford, David R; Clark, Robert K F
2003-01-01
Acrylic resin complete dentures undergo dimensional changes during polymerization. Techniques with injection molding and polymerization and microwave polymerization are reported to reduce these changes and thereby improve clinical fit. These dimensional changes need to be quantified. The purpose of this study was to compare differences in dimensional changes of simulated maxillary complete dentures during polymerization and storage in water after injection molding and conventional polymerization, or microwave polymerization against a control of conventionally packed and polymerized simulated maxillary complete dentures. Forty identical maxillary denture bases were prepared in dental wax with anatomic teeth. They were invested and the wax eliminated from the molds. Ten specimens each were randomly assigned to 1 of 4 groups. Group 1 was compression molded and conventionally polymerized; group 2 was injection molded and conventionally polymerized (Success); group 3 was injection molded and microwave polymerized (Acron MC); and group 4 was injection molded and microwave polymerized (Microbase). Intermolar width and changes in vertical dimension of occlusion, were determined after polymerization and after storage in water for 28 days. Measurements in triplicate were made between points scribed on the second molar teeth with a traveling microscope (accurate to 0.005 mm). Vertical dimension of occlusion was measured between points scribed on the upper and lower members of an articulator by use of an internal micrometer (accurate to 0.05 mm). Data were analyzed by use of a 1-way analysis of variance with Tukey post-hoc contrasts (P <.05). Polymerization contractions (intermolar widths) for each group were: group 1, -0.24%; group 2, -0.27%; group 3, -0.35%; and group 4, -0.37%. The Microbase specimens had greater shrinkage than conventionally polymerized specimens, but there were no significant differences between the groups. All injection methods had less postpolymerization increase in vertical dimension of occlusion (0.63 to 0.41 mm) than the conventional Trevalon control (0.74 mm), but only group 4 was significantly different (P<.004). After storage in water for 28 days, all specimens increased in vertical dimension of occlusion (0.10% to 0.16%) from polymerization techniques, but there were no significant differences between groups. Within the limitations of this study, injection molding resulted in a slightly less increase of vertical dimension of occlusion than conventional polymerization techniques, the difference being significant for Microbase compared with the conventional Trevalon control.
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Study of injection molded microcellular polyamide-6 nanocomposites
Mingjun Yuan; Lih-Sheng Turng; Shaoqin Gong; Daniel Caulfield; Chris Hunt; Rick Spindler
2004-01-01
This study aims to explore the processing benefits and property improvements of combining nanocomposites with microcellular injection molding. The microcellular nanocomposite processing was performed on an injection-molding machine equipped with a commercially available supercritical fluid (SCF) system. The molded samples produced based on the Design of Experiments (...
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Fuel cell collector plate and method of fabrication
Braun, James C.; Zabriskie, Jr., John E.; Neutzler, Jay K.; Fuchs, Michel; Gustafson, Robert C.
2001-01-01
An improved molding composition is provided for compression molding or injection molding a current collector plate for a polymer electrolyte membrane fuel cell. The molding composition is comprised of a polymer resin combined with a low surface area, highly-conductive carbon and/or graphite powder filler. The low viscosity of the thermoplastic resin combined with the reduced filler particle surface area provide a moldable composition which can be fabricated into a current collector plate having improved current collecting capacity vis-a-vis comparable fluoropolymer molding compositions.
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Battiste, Richard L.
2007-12-25
Methods and apparatus are described for characterizing the temporal-spatial properties of a dynamic fluid front within a mold space while the mold space is being filled with fluid. A method includes providing a mold defining a mold space and having one or more openings into the mold space; heating a plurality of temperature sensors that extend into the mold space; injecting a fluid into the mold space through the openings, the fluid experiencing a dynamic fluid front while filling the mold space with the fluid; and characterizing temporal-spatial properties of the dynamic fluid front by monitoring a temperature of each of the plurality of heated temperature sensors while the mold space is being filled with the fluid. An apparatus includes a mold defining a mold space; one or more openings for introducing a fluid into the mold space and filling the mold space with the fluid, the fluid experiencing a dynamic fluid front while filling the mold space; a plurality of heated temperature sensors extending into the mold space; and a computer coupled to the plurality of heated temperature sensors for characterizing the temporal-spatial properties of the dynamic fluid front.
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Development of integrated control system for smart factory in the injection molding process
NASA Astrophysics Data System (ADS)
Chung, M. J.; Kim, C. Y.
2018-03-01
In this study, we proposed integrated control system for automation of injection molding process required for construction of smart factory. The injection molding process consists of heating, tool close, injection, cooling, tool open, and take-out. Take-out robot controller, image processing module, and process data acquisition interface module are developed and assembled to integrated control system. By adoption of integrated control system, the injection molding process can be simplified and the cost for construction of smart factory can be inexpensive.
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Interface conditions of two-shot molded parts
DOE Office of Scientific and Technical Information (OSTI.GOV)
Kisslinger, Thomas, E-mail: thomas.kisslinger@pccl.at; Bruckmoser, Katharina, E-mail: katharina.bruckmoser@unileoben.ac.at; Resch, Katharina, E-mail: katharina.resch@unileoben.ac.at
2014-05-15
The focus of this work is on interfaces of two-shot molded parts. It is well known that e.g. material combination, process parameters and contact area structures show significant effects on the bond strength of multi-component injection molded parts. To get information about the bond strength at various process parameter settings and material combinations a test mold with core back technology was used to produce two-component injection molded tensile test specimens. At the core back process the different materials are injected consecutively, so each component runs through the whole injection molding cycle (two-shot process). Due to this consecutive injection molding processes,more » a cold interface is generated. This is defined as overmolding of a second melt to a solidified polymer preform. Strong interest lies in the way the interface conditions change during the adhesion formation between the individual components. Hence the interface conditions were investigated by computed tomography and Raman spectroscopy. By analyzing these conditions the understanding of the adhesion development during the multi-component injection molding was improved.« less
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Investigation of the adhesion interface obtained through two-component injection molding
NASA Astrophysics Data System (ADS)
Fetecau, Catalin; Stan, Felicia; Dobrea, Daniel
2011-01-01
In this paper we study the interface strength obtained through two-component (2C) injection molding of LDPE-HDPE polymers. First, numerical simulation of the over-molding process is carried out using Moldflow technology. Second, butt-joint specimens were produced by over-molding under different process condition, and tested. Two injection sequences were considered, injection of LDPE on HDPE polymer, and HDLE on LDPE, respectively. To investigate the effects of the mold surface roughness on the polymers adhesion at interface, different inserts with different roughness are employed.
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Injection molding of silicon carbide capable of being sintered without pressure
NASA Technical Reports Server (NTRS)
Muller-Zell, A.; Schwarzmeier, R.
1984-01-01
The most suitable SiC mass for injection molding of SiC articles (for subsequent pressureless sintering) consisted of beta SiC 84, a wax mixture 8, and polyethylene or polystyrene 8 parts. The most effective method for adding the binders was by dissolving them in a solvent and subsequent evaporation. The sequence of component addition was significant, and all parameters were optimized together rather than individually.
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APPARATUS AND METHOD FOR INJECTION CASTING
Shuck, A.B.
1960-09-13
S>A single-chamber metal casting apparatus is described wherein molten metal in a vertically movable container can be brought directly into contact with molds. By increasing the gas pressure within the chamber the metal is forced upward into the molds.
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Heidari, Behzad Shiroud; Oliaei, Erfan; Shayesteh, Hadi; Davachi, Seyed Mohammad; Hejazi, Iman; Seyfi, Javad; Bahrami, Mozhgan; Rashedi, Hamid
2017-01-01
In this study, injection molding of three poly lactic acid (PLA) based bone screws was simulated and optimized through minimizing the shrinkage and warpage of the bone screws. The optimization was carried out by investigating the process factors such as coolant temperature, mold temperature, melt temperature, packing time, injection time, and packing pressure. A response surface methodology (RSM), based on the central composite design (CCD), was used to determine the effects of the process factors on the PLA based bone screws. Upon applying the method of maximizing the desirability function, optimization of the factors gave the lowest warpage and shrinkage for nanocomposite PLA bone screw (PLA9). Moreover, PLA9 has the greatest desirability among the selected materials for bone screw injection molding. Meanwhile, a finite element analysis (FE analysis) was also performed to determine the force values and concentration points which cause yielding of the screws under certain conditions. The Von-Mises stress distribution showed that PLA9 screw is more resistant against the highest loads as compared to the other ones. Finally, according to the results of injection molding simulations, the design of experiments (DOE) and structural analysis, PLA9 screw is recommended as the best candidate for the production of biomedical materials among all the three types of screws. Copyright © 2016 Elsevier Ltd. All rights reserved.
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DOE Office of Scientific and Technical Information (OSTI.GOV)
Peters, E.M.; Masso, J.D.
This project involved the manufacturing of curved-faceted, injection-molded, four-element Fresnel lens parquets for concentrating photovoltaic arrays. Previous efforts showed that high-efficiency (greater than 82%) Fresnel concentrators could be injection molded. This report encompasses the mold design, molding, and physical testing of a four-lens parquet for a solar photovoltaic concentrator system.
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Composite materials molding simulation for purpose of automotive industry
NASA Astrophysics Data System (ADS)
Grabowski, Ł.; Baier, A.; Majzner, M.; Sobek, M.
2016-08-01
Composite materials loom large increasingly important role in the overall industry. Composite material have a special role in the ever-evolving automotive industry. Every year the composite materials are used in a growing number of elements included in the cars construction. Development requires the search for ever new applications of composite materials in areas where previously were used only metal materials. Requirements for modern solutions, such as reducing the weight of vehicles, the required strength and vibration damping characteristics go hand in hand with the properties of modern composite materials. The designers faced the challenge of the use of modern composite materials in the construction of bodies of power steering systems in vehicles. The initial choice of method for producing composite bodies was the method of molding injection of composite material. Molding injection of polymeric materials is a widely known and used for many years, but the molding injection of composite materials is a relatively new issue, innovative, it is not very common and is characterized by different conditions, parameters and properties in relation to the classical method. Therefore, for the purpose of selecting the appropriate composite material for injection for the body of power steering system computer analysis using Siemens NX 10.0 environment, including Moldex 3d and EasyFill Advanced tool to simulate the injection of materials from the group of possible solutions were carried out. Analyses were carried out on a model of a modernized wheel case of power steering system. During analysis, input parameters, such as temperature, pressure injectors, temperature charts have been analysed. An important part of the analysis was to analyse the propagation of material inside the mold during injection, so that allowed to determine the shape formability and the existence of possible imperfections of shapes and locations air traps. A very important parameter received from computer analysis was to determine the occurrence of the shrinkage of the material, which significantly affects the behaviour of the assumed geometry of the tested component. It also allowed the prediction of existence of shrincage of material during the process of modelling the shape of body. The next step was to analyse the numerical analysis results received from Siemens NX 10 and Moldex 3D EasyFlow Advanced environment. The process of injection were subjected to shape of prototype body of power steering. The material used in process of injection was similar to one of excepted material to be used in process of molding. Nextly, the results were analysed in purpose of geometry, where samples has aberrations in comparison to a given shape of mold. The samples were also analysed in terms of shrinkage. Research and results were described in detail in this paper.
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Predicting shrinkage and warpage in injection molding: Towards automatized mold design
NASA Astrophysics Data System (ADS)
Zwicke, Florian; Behr, Marek; Elgeti, Stefanie
2017-10-01
It is an inevitable part of any plastics molding process that the material undergoes some shrinkage during solidification. Mainly due to unavoidable inhomogeneities in the cooling process, the overall shrinkage cannot be assumed as homogeneous in all volumetric directions. The direct consequence is warpage. The accurate prediction of such shrinkage and warpage effects has been the subject of a considerable amount of research, but it is important to note that this behavior depends greatly on the type of material that is used as well as the process details. Without limiting ourselves to any specific properties of certain materials or process designs, we aim to develop a method for the automatized design of a mold cavity that will produce correctly shaped moldings after solidification. Essentially, this can be stated as a shape optimization problem, where the cavity shape is optimized to fulfill some objective function that measures defects in the molding shape. In order to be able to develop and evaluate such a method, we first require simulation methods for the diffierent steps involved in the injection molding process that can represent the phenomena responsible for shrinkage and warpage ina sufficiently accurate manner. As a starting point, we consider the solidification of purely amorphous materials. In this case, the material slowly transitions from fluid-like to solid-like behavior as it cools down. This behavior is modeled using adjusted viscoelastic material models. Once the material has passed a certain temperature threshold during cooling, any viscous effects are neglected and the behavior is assumed to be fully elastic. Non-linear elastic laws are used to predict shrinkage and warpage that occur after this point. We will present the current state of these simulation methods and show some first approaches towards optimizing the mold cavity shape based on these methods.
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Robison, Nathan E; Tantbirojn, Daranee; Versluis, Antheunis; Cagna, David R
2016-08-01
Denture tooth fracture or debonding remains a common problem in removable prosthodontics. The purpose of this in vitro study was to explore factors determining failure strengths for combinations of different denture tooth designs (shape, materials) and injection or compression molded denture base resins. Three central incisor denture tooth designs were tested: nanohybrid composite (NHC; Ivoclar Phonares II), interpenetrating network (IPN; Dentsply Portrait), and microfiller reinforced polyacrylic (MRP; VITA Physiodens). Denture teeth of each type were processed on an injection molded resin (IvoBase HI; Ivoclar Vivadent AG) or a compression molded resin (Lucitone 199; Dentsply Intl) (n=11 or 12). The denture teeth were loaded at 45 degrees on the incisal edge. The failure load was recorded and analyzed with 2-way ANOVA (α=.05), and the fracture mode was categorized from observed fracture surfaces as cohesive, adhesive, or mixed failure. The following failure loads (mean ±SD) were recorded: NHC/injection molded 280 ±52 N; IPN/injection molded 331 ±41 N; MRP/injection molded 247 ±23 N; NHC/compression molded 204 ±31 N; IPN/compression molded 184 ±17 N; MRP/compression molded 201 ±16 N. Injection molded resin yielded significantly higher failure strength for all denture teeth (P<.001), among which IPN had the highest strength. Failure was predominantly cohesive in the teeth, with the exception of mixed mode for the IPN/compression group. When good bonding was achieved, the strength of the structure (denture tooth/base resin combination) was determined by the strength of the denture teeth, which may be affected by the processing technique. Copyright © 2016 Editorial Council for the Journal of Prosthetic Dentistry. Published by Elsevier Inc. All rights reserved.
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Battiste, Richard L
2013-12-31
Methods and apparatus are described for characterizing the temporal-spatial properties of a dynamic fluid front within a mold space while the mold space is being filled with fluid. A method includes providing a mold defining a mold space and having one or more openings into the mold space; heating a plurality of temperature sensors that extend into the mold space; injecting a fluid into th emold space through the openings, the fluid experiencing a dynamic fluid front while filling the mold space with a fluid; and characterizing temporal-spatial properties of the dynamic fluid front by monitoring a termperature of each of the plurality of heated temperature sensors while the mold space is being filled with the fluid. An apparatus includes a mold defining a mold space; one or more openings for introducing a fluid into th emold space and filling the mold space with the fluid, the fluid experiencing a dynamic fluid front while filling the mold space; a plurality of heated temperature sensors extending into the mold space; and a computer coupled to the plurality of heated temperature sensors for characterizing the temporal-spatial properties of the dynamic fluid front.
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Herman Winata; Lih-Sheng Turng; Daniel F. Caulfield; Tom Kuster; Rick Spindler; Rod Jacobson
2003-01-01
In this study, a cellulose-fiber-reinforced Polyamide-6 (PA-6) composite, a hybrid composite (PA-6/cellulose/Wollastonite), and the neat PA-6 resin were injection molded into ASTM testâbar samples with conventional and microcellular injection molding. The impact and tensile strengths of molded samples were measured and the Scanning Electron Microscopy (SEM) images were...
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Wilson, S E; Brubaker, R F
1987-01-01
The possibility that injection-molded intraocular lenses (IOLs) with imperfections called iridescent clefts could have a decreased threshold to neodymium: YAG (Nd:YAG) laser-induced damage was investigated. Thresholds for Nd:YAG laser-induced damage were determined for injection-molded and lathe-cut polymethylmethacrylate lenses. When aimed at a membrane in contact with a posterior convex surface, the average thresholds were 0.96 +/- 0.18 mJ (Standard deviation [SD]) and 1.80 +/- 0.55 mJ, respectively. The difference was significant at P = 0.001. When injection-molding polymethylmethacrylate was used to make lathe-cut IOLs, very few iridescent clefts were present, and the threshold to Nd:YAG laser-induced damage was 0.94 +/- 0.25 mJ. Iridescent clefts are therefore produced during the injection-molding process but they do not lower the threshold to Nd:YAG laser-induced damage. Rather, the reduced threshold in injection-molded lenses is most probably a result of the polymethylmethacrylate used in their manufacture. Clinically, iridescent clefts in a lens suggest that it has been manufactured by an injection-molding process and that Nd:YAG laser posterior capsulotomy must be performed at the lowest possible energy level to avoid damage.
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Cho, E; Kim, B; Choi, S; Han, J; Jin, J; Han, J; Lim, J; Heo, Y; Kim, S; Sung, G Y; Kang, S
2011-01-01
This paper introduces technology to fabricate a guided mode resonance filter biochip using injection molding. Of the various nanofabrication processes that exist, injection molding is the most suitable for the mass production of polymer nanostructures. Fabrication of a nanograting pattern for guided mode resonance filters by injection molding requires a durable metal stamp, because of the high injection temperature and pressure. Careful consideration of the optimized process parameters is also required to achieve uniform sub-wavelength gratings with high fidelity. In this study, a metallic nanostructure pattern to be used as the stamp for the injection molding process was fabricated using electron beam lithography, a UV nanoimprinting process, and an electroforming process. A one-dimensional nanograting substrate was replicated by injection molding, during which the process parameters were controlled. To evaluate the geometric quality of the injection molded nanograting patterns, the surface profile of the fabricated nanograting for different processing conditions was analyzed using an atomic force microscope and a scanning electron microscope. Finally, to demonstrate the feasibility of the proposed process for fabricating guided mode resonance filter biochips, a high-refractive-index material was deposited on the polymer nanograting and its guided mode resonance characteristics were analyzed.
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Effects of mold geometry on fiber orientation of powder injection molded metal matrix composites
DOE Office of Scientific and Technical Information (OSTI.GOV)
Ahmad, Faiz, E-mail: faizahmad@petronas.com.my; Aslam, Muhammad, E-mail: klaira73@gmail.com; Altaf, Khurram, E-mail: khurram.altaf@petronas.com.my
2015-07-22
Fiber orientations in metal matrix composites have significant effect on improving tensile properties. Control of fiber orientations in metal injection molded metal composites is a difficult task. In this study, two mold cavities of dimensions 6x6x90 mm and 10x20x180 mm were used for comparison of fiber orientation in injection molded metal composites test parts. In both mold cavities, convergent and divergent flows were developed by modifying the sprue dimensions. Scanning electron microscope (SEM) was used to examine the fiber orientations within the test samples. The results showed highly aligned fiber in injection molded test bars developed from the convergent melt flow. Randommore » orientation of fibers was noted in the composites test bars produced from divergent melt flow.« less
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NASA Astrophysics Data System (ADS)
Daldoul, Wafa; Toulorge, Thomas; Vincent, Michel
2017-10-01
The cost and quality of complex parts manufactured by thermoplastic injection is traditionally limited by design constraints on the cooling system of the mold. A possible solution is to create the mold by additive manufacturing, which makes it possible to freely design the cooling channels. Such molds normally contain hollow parts (alveoli) in order to decrease their cost. However, the complex geometry of the cooling channels and the alveoli makes it difficult to predict the performance of the cooling system. This work aims to compute the heat exchanges between the polymer, the mold and the cooling channels with complex geometries. An Immersed Volume approach is taken, where the different parts of the domain (i.e. the polymer, the cooling channels, the alveoli and the mold) are represented by level-sets and the thermo-mechanical properties of the materials vary smoothly at the interface between the parts. The energy and momentum equations are solved by a stabilized Finite Element method. In order to accurately resolve the large variations of material properties and the steep temperature gradients at interfaces, state-of-the art anisotropic mesh refinement techniques are employed. The filling stage of the process is neglected. In a first step, only the heat equation is solved, so that the packing stage is also disregarded. In a second step, thermo-mechanical effects occurring in the polymer during the packing stage are taken into account, which results in the injection of an additional amount of polymer that significantly influences the temperature evolution. The method is validated on the simple geometry of a center-gated disk and compared with experimental measurements. The agreement is very good. Simulations are performed on an industrial case which illustrates the ability of the method to deal with complex geometries.
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Inexpensive 3dB coupler for POF communication by injection-molding production
NASA Astrophysics Data System (ADS)
Haupt, M.; Fischer, U. H. P.
2011-01-01
POFs (polymer optical fibers) gradually replace traditional communication media such as copper and glass within short distance communication systems. Primarily, this is due to their cost-effectiveness and easy handling. POFs are used in various fields of optical communication, e.g. the automotive sector or in-house communication. So far, however, only a few key components for a POF communication network are available. Even basic components, such as splices and couplers, are fabricated manually. Therefore, these circumstances result in high costs and fluctuations in components' performance. Available couplers have high insertion losses due to their manufacturing method. This can only be compensated by higher power budgets. In order to produce couplers with higher performances new fabrication methods are indispensable. A cheap and effective way to produce couplers for POF communication systems is injection molding. The paper gives an overview of couplers available on market, compares their performances, and shows a way to produce couplers by means of injection molding.
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Material flow data for numerical simulation of powder injection molding
NASA Astrophysics Data System (ADS)
Duretek, I.; Holzer, C.
2017-01-01
The powder injection molding (PIM) process is a cost efficient and important net-shape manufacturing process that is not completely understood. For the application of simulation programs for the powder injection molding process, apart from suitable physical models, exact material data and in particular knowledge of the flow behavior are essential in order to get precise numerical results. The flow processes of highly filled polymers are complex. Occurring effects are very hard to separate, like shear flow with yield stress, wall slip, elastic effects, etc. Furthermore, the occurrence of phase separation due to the multi-phase composition of compounds is quite probable. In this work, the flow behavior of a 316L stainless steel feedstock for powder injection molding was investigated. Additionally, the influence of pre-shearing on the flow behavior of PIM-feedstocks under practical conditions was examined and evaluated by a special PIM injection molding machine rheometer. In order to have a better understanding of key factors of PIM during the injection step, 3D non-isothermal numerical simulations were conducted with a commercial injection molding simulation software using experimental feedstock properties. The simulation results were compared with the experimental results. The mold filling studies amply illustrate the effect of mold temperature on the filling behavior during the mold filling stage. Moreover, the rheological measurements showed that at low shear rates no zero shear viscosity was observed, but instead the viscosity further increased strongly. This flow behavior could be described with the Cross-WLF approach with Herschel-Bulkley extension very well.
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Injection Molding Parameters Calculations by Using Visual Basic (VB) Programming
NASA Astrophysics Data System (ADS)
Tony, B. Jain A. R.; Karthikeyen, S.; Alex, B. Jeslin A. R.; Hasan, Z. Jahid Ali
2018-03-01
Now a day’s manufacturing industry plays a vital role in production sectors. To fabricate a component lot of design calculation has to be done. There is a chance of human errors occurs during design calculations. The aim of this project is to create a special module using visual basic (VB) programming to calculate injection molding parameters to avoid human errors. To create an injection mold for a spur gear component the following parameters have to be calculated such as Cooling Capacity, Cooling Channel Diameter, and Cooling Channel Length, Runner Length and Runner Diameter, Gate Diameter and Gate Pressure. To calculate the above injection molding parameters a separate module has been created using Visual Basic (VB) Programming to reduce the human errors. The outcome of the module dimensions is the injection molding components such as mold cavity and core design, ejector plate design.
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NASA Astrophysics Data System (ADS)
Botos, J.; Murail, N.; Heidemeyer, P.; Kretschmer, K.; Ulmer, B.; Zentgraf, T.; Bastian, M.; Hochrein, T.
2014-05-01
The typical offline color measurement on injection molded or pressed specimens is a very expensive and time-consuming process. In order to optimize the productivity and quality, it is desirable to measure the color already during the production. Therefore several systems have been developed to monitor the color e.g. on melts, strands, pellets, the extrudate or injection molded part already during the process. Different kinds of inline, online and atline methods with their respective advantages and disadvantages will be compared. The criteria are e.g. the testing time, which ranges from real-time to some minutes, the required calibration procedure, the spectral resolution and the final measuring precision. The latter ranges between 0.05 to 0.5 in the CIE L*a*b* system depending on the particular measurement system. Due to the high temperatures in typical plastics processes thermochromism of polymers and dyes has to be taken into account. This effect can influence the color value in the magnitude of some 10% and is barely understood so far. Different suitable methods to compensate thermochromic effects during compounding or injection molding by using calibration curves or artificial neural networks are presented. Furthermore it is even possible to control the color during extrusion and compounding almost in real-time. The goal is a specific developed software for adjusting the color recipe automatically with the final objective of a closed-loop control.
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Testing single point incremental forming molds for thermoforming operations
NASA Astrophysics Data System (ADS)
Afonso, Daniel; de Sousa, Ricardo Alves; Torcato, Ricardo
2016-10-01
Low pressure polymer processing processes as thermoforming or rotational molding use much simpler molds then high pressure processes like injection. However, despite the low forces involved with the process, molds manufacturing for this operations is still a very material, energy and time consuming operation. The goal of the research is to develop and validate a method for manufacturing plastically formed sheets metal molds by single point incremental forming (SPIF) operation for thermoforming operation. Stewart platform based SPIF machines allow the forming of thick metal sheets, granting the required structural stiffness for the mold surface, and keeping the short lead time manufacture and low thermal inertia.
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NASA Astrophysics Data System (ADS)
Chailly, M.; Charmeau, J.-Y.; Bereaux, Y.; Monasse, B.
2007-04-01
Due to increasing expectations from the market, the aspect of molded parts has to be improved constantly. Some of the defects observed on these parts such as weldlines are related to the filling stage. To limit this, we investigated the influence on weldlines using various surface deposits on the mold surface, mainly PVD and PACVD deposits : Chromium nitride (CrN), Titanium nitride (TiN), Diamond like Carbon (DLC), Chromium and polished steel (PG) on an instrumented plate mold. Injection campaign was led on three polymers which differ in terms of nature (amorphous, semi-crystalline, copolymers). We studied the evolution of the dimensions of weldlines appearing on the plate using the same injection parameters for a given polymer, but with various deposits and thicknesses. Another aspect that had been investigated is the morphology of the weldline through the thickness of the part, depending on polymer nature. Adhesion of polymer at the flow front with the mold surface proved to change. The modification of the initial contact in the filling stage and thus the thermal resistance at the mold implied a change in the process, increasing or reducing the pressure loss in the flow and differential shrinkage in the final part. The induced impact on dimensions of the weldlines allowed to distinguish which surface treatments were able to reduce the defect. A complementary study was led on both polymers in molten state and deposits in terms of wetting using a sessile drop method to confirm the adhesion at the polymer/mold interface. This study proved the influence of the use of surface treatments has clearly an impact on the filling stage of the injection molding process, and it is necessary to get a better knowledge of the interactions between physical adhesion, tribology of polymer/mold contact, and thermal properties of the coatings and their impact on solidification of the polymer.
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NASA Astrophysics Data System (ADS)
Rupetsov, Velko; Mishev, Georgi; Dishliev, Stefan; Kopanov, Viktor; Chitanov, Vassiliy; Kolaklieva, Lilyana; Pashinski, Chavdar
2017-02-01
Injection molds used in production of plastic components are subject of heavy abrasion wear. The increase of their wear resistance significantly reduces the production cost. In the current work are presented research results of the wear resistance of injection molds made of steel 1.2343, coated with Ti/TiN/TiCN/nc-TiCN: a-C/nc-TiC:a -C/a-C. The study of the wear rate was done using the volumetric method and the influence of the trace length was investigated. The coating thickness, nanohardness, elastic modulus and adhesion were also tested. The coating was applied on unhardened ground specimens, hardened ground specimens and hardened polished specimens.
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Dynamic Feed Control For Injection Molding
Kazmer, David O.
1996-09-17
The invention provides methods and apparatus in which mold material flows through a gate into a mold cavity that defines the shape of a desired part. An adjustable valve is provided that is operable to change dynamically the effective size of the gate to control the flow of mold material through the gate. The valve is adjustable while the mold material is flowing through the gate into the mold cavity. A sensor is provided for sensing a process condition while the part is being molded. During molding, the valve is adjusted based at least in part on information from the sensor. In the preferred embodiment, the adjustable valve is controlled by a digital computer, which includes circuitry for acquiring data from the sensor, processing circuitry for computing a desired position of the valve based on the data from the sensor and a control data file containing target process conditions, and control circuitry for generating signals to control a valve driver to adjust the position of the valve. More complex embodiments include a plurality of gates, sensors, and controllable valves. Each valve is individually controllable so that process conditions corresponding to each gate can be adjusted independently. This allows for great flexibility in the control of injection molding to produce complex, high-quality parts.
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NASA Astrophysics Data System (ADS)
Ellingham, Thomas; Kharbas, Hrishikesh; Manitiu, Mihai; Scholz, Guenter; Turng, Lih-Sheng
2018-03-01
A three-stage molding process involving microcellular injection molding with core retraction and an "out-of-mold" expansion was developed to manufacture thermoplastic polyurethane into lightweight foams of varying local densities, microstructures, and mechanical properties in the same microcellular injection molded part. Two stages of cavity expansion through sequential core retractions and a third expansion in a separate mold at an elevated temperature were carried out. The densities varied from 0.25 to 0.42 g/cm3 (77% to 62% weight reduction). The mechanical properties varied as well. Cyclic compressive strengths and hysteresis loss ratios, together with the microstructures, were characterized and reported.
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Computer-aided injection molding system
NASA Astrophysics Data System (ADS)
Wang, K. K.; Shen, S. F.; Cohen, C.; Hieber, C. A.; Isayev, A. I.
1982-10-01
Achievements are reported in cavity-filling simulation, modeling viscoelastic effects, measuring and predicting frozen-in birefringence in molded parts, measuring residual stresses and associated mechanical properties of molded parts, and developing an interactive mold-assembly design program and an automatic NC maching data generation and verification program. The Cornell Injection Molding Program (CIMP) consortium is discussed as are computer user manuals that have been published by the consortium. Major tasks which should be addressed in future efforts are listed, including: (1) predict and experimentally determine the post-fillin behavior of thermoplastics; (2) simulate and experimentally investigate the injection molding of thermosets and filled materials; and (3) further investigate residual stresses, orientation and mechanical properties.
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Fabrication of injection molded sintered alpha SiC turbine components
NASA Technical Reports Server (NTRS)
Storm, R. S.; Ohnsorg, R. W.; Frechette, F. J.
1981-01-01
Fabrication of a sintered alpha silicon carbide turbine blade by injection molding is described. An extensive process variation matrix was carried out to define the optimum fabrication conditions. Variation of molding parameters had a significant impact on yield. Turbine blades were produced in a reasonable yield which met a rigid quality and dimensional specification. Application of injection molding technology to more complex components such as integral rotors is also described.
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Mathematical modeling of the process of filling a mold during injection molding of ceramic products
NASA Astrophysics Data System (ADS)
Kulkov, S. N.; Korobenkov, M. V.; Bragin, N. A.
2015-10-01
Using the software package Fluent it have been predicted of the filling of a mold in injection molding of ceramic products is of great importance, because the strength of the final product is directly related to the presence of voids in the molding, making possible early prediction of inaccuracies in the mold prior to manufacturing. The calculations were performed in the formulation of mathematical modeling of hydrodynamic turbulent process of filling a predetermined volume of a viscous liquid. The model used to determine the filling forms evaluated the influence of density and viscosity of the feedstock, and the injection pressure on the mold filling process to predict the formation of voids in the area caused by the shape defect geometry.
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Topology optimization applied to the design of cooling channels for plastic injection
NASA Astrophysics Data System (ADS)
Muñoz, D. A.; Arango, J. P.; González, C.; Puerto, E.; Garzón, M.
2018-04-01
In this paper, topology optimization is applied to design cooling channels in a mold of structural steel. The problem was implemented in COMSOL multiphysics, where two physics were coupled, heat transfer and solid mechanics. The optimization objective is to maximize the conduction heat flux in the mold and minimize the deformations when the plastic is injected. In order to find an optimal geometry for this objective, a density-based method was implemented into the nonlinear program (NLP) for which feasible results were found.
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Applications of nanocomposites and woodfiber plastics for microcellular injection molding
Lih-Sheng Turng; Mingjun Yuan; Hrishikesh Kharbas; Herman Winata; Daniel F. Caulfield
2003-01-01
The paper reviews the processing advantages and challenges of microcellular injection molding and presents recent research results on applications of nanocomposites and woodfiber-plastic composites as well as new process develop for the microcellular injection molding process. In particular, two types of polyamide (PA-6) neat resins and their filled counterparts, such...
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An in-mold packaging process for plastic fluidic devices.
Yoo, Y E; Lee, K H; Je, T J; Choi, D S; Kim, S K
2011-01-01
Micro or nanofluidic devices have many channel shapes to deliver chemical solutions, body fluids or any fluids. The channels in these devices should be covered to prevent the fluids from overflowing or leaking. A typical method to fabricate an enclosed channel is to bond or weld a cover plate to a channel plate. This solid-to-solid bonding process, however, takes a considerable amount of time for mass production. In this study, a new process for molding a cover layer that can enclose open micro or nanochannels without solid-to-solid bonding is proposed and its feasibility is estimated. First, based on the design of a model microchannel, a brass microchannel master core was machined and a plastic microchannel platform was injection-molded. Using this molded platform, a series of experiments was performed for four process or mold design parameters. Some feasible conditions were successfully found to enclosed channels without filling the microchannels for the injection molding of a cover layer over the plastic microchannel platform. In addition, the bond strength and seal performance were estimated in a comparison with those done by conventional bonding or welding processes.
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Huang, Fu-Chun; Chen, Yih-Far; Lee, Gwo-Bin
2007-04-01
This study presents a new packaging method using a polyethylene/thermoplastic elastomer (PE/TPE) film to seal an injection-molded CE chip made of either poly(methyl methacrylate) (PMMA) or polycarbonate (PC) materials. The packaging is performed at atmospheric pressure and at room temperature, which is a fast, easy, and reliable bonding method to form a sealed CE chip for chemical analysis and biomedical applications. The fabrication of PMMA and PC microfluidic channels is accomplished by using an injection-molding process, which could be mass-produced for commercial applications. In addition to microfluidic CE channels, 3-D reservoirs for storing biosamples, and CE buffers are also formed during this injection-molding process. With this approach, a commercial CE chip can be of low cost and disposable. Finally, the functionality of the mass-produced CE chip is demonstrated through its successful separation of phiX174 DNA/HaeIII markers. Experimental data show that the S/N for the CE chips using the PE/TPE film has a value of 5.34, when utilizing DNA markers with a concentration of 2 ng/microL and a CE buffer of 2% hydroxypropyl-methylcellulose (HPMC) in Tris-borate-EDTA (TBE) with 1% YO-PRO-1 fluorescent dye. Thus, the detection limit of the developed chips is improved. Lastly, the developed CE chips are used for the separation and detection of PCR products. A mixture of an amplified antibiotic gene for Streptococcus pneumoniae and phiX174 DNA/HaeIII markers was successfully separated and detected by using the proposed CE chips. Experimental data show that these DNA samples were separated within 2 min. The study proposed a promising method for the development of mass-produced CE chips.
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An apparatus for in situ x-ray scattering measurements during polymer injection molding.
Rendon, Stanley; Fang, Jun; Burghardt, Wesley R; Bubeck, Robert A
2009-04-01
We report a novel instrument for synchrotron-based in situ x-ray scattering measurements during injection molding processing. It allows direct, real-time monitoring of molecular-scale structural evolution in polymer materials undergoing a complex processing operation. The instrument is based on a laboratory-scale injection molding machine, and employs customized mold tools designed to allow x-ray access during mold filling and subsequent solidification, while providing sufficient robustness to withstand high injection pressures. The use of high energy, high flux synchrotron radiation, and a fast detector allows sufficiently rapid data acquisition to resolve time-dependent orientation dynamics in this transient process. Simultaneous monitoring of temperature and pressure signals allows transient scattering data to be referenced to various stages of the injection molding cycle. Representative data on a commercial liquid crystalline polymer, Vectra(R) B950, are presented to demonstrate the features of this apparatus; however, it may find application in a wide range of polymeric materials such as nanocomposites, semicrystalline polymers and fiber-reinforced thermoplastics.
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Fabrication of sinterable silicon nitride by injection molding
NASA Technical Reports Server (NTRS)
Quackenbush, C. L.; French, K.; Neil, J. T.
1982-01-01
Transformation of structural ceramics from the laboratory to production requires development of near net shape fabrication techniques which minimize finish grinding. One potential technique for producing large quantities of complex-shaped parts at a low cost, and microstructure of sintered silicon nitride fabricated by injection molding is discussed and compared to data generated from isostatically dry-pressed material. Binder selection methodology, compounding of ceramic and binder components, injection molding techniques, and problems in binder removal are discussed. Strength, oxidation resistance, and microstructure of sintered silicon nitride fabricated by injection molding is discussed and compared to data generated from isostatically dry-pressed material.
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Processing study of injection molding of silicon nitride for engine applications
NASA Technical Reports Server (NTRS)
Rorabaugh, M. E.; Yeh, H. C.
1985-01-01
The high hardness of silicon nitride, which is currently under consideration as a structural material for such hot engine components as turbine blades, renders machining of the material prohibitively costly; the near net shape forming technique of injection molding is accordingly favored as a means for component fabrication. Attention is presently given to the relationships between injection molding processing parameters and the resulting microstructural and mechanical properties of the resulting engine parts. An experimental program has been conducted under NASA sponsorship which tests the quality of injection molded bars of silicon nitride at various stages of processing.
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DOE Office of Scientific and Technical Information (OSTI.GOV)
Kumar, A.; Ghoshdastidar, P.S.
1999-07-01
In this paper, numerical simulation of injection mold-filling during the production of a cylindrical object under isothermal and non-isothermal conditions is presented. The material of the object is low density polyethylene (LDPE) following power-law viscosity model for non-zero shear rate zone. However, where shear rate becomes zero, zero-shear viscosity value has been used. Three cases have been considered, namely (1) Isothermal filling at constant injection pressure, (2) Isothermal filling at constant flow rate, and (3) Non-isothermal filling at constant flow rate. For the case-(3), the viscosity of LDPE is also a function of temperature. The material of the mold ismore » steel. For the non-isothermal filling, the concept of melt-mold thermal contact resistance coefficient has been incorporated in the model. The length and diameter of the body in all three cases have been taken as 0.254 m and 0.00508 m respectively. The finite-difference method has been used to solve the governing differential equations for the processes. The results show excellent agreement with the corresponding equations for the processes. The results show excellent agreement with the corresponding analytical solutions for the first two cases showing the correctness of the numerical method. The simulation results for non-isothermal filling show physically realistic trends and lend insight into various important aspects of mold-filling including frozen skin layer.« less
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Modeling of magnetic particle orientation in magnetic powder injection molding
NASA Astrophysics Data System (ADS)
Doo Jung, Im; Kang, Tae Gon; Seul Shin, Da; Park, Seong Jin
2018-03-01
The magnetic micro powder orientation under viscous shear flow has been analytically understood and characterized into a new analytical orientation model for a powder injection molding process. The effects of hydrodynamic force from the viscous flow, external magnetic force and internal dipole-dipole interaction were considered to predict the orientation under given process conditions. Comparative studies with a finite element method proved the calculation validity with a partial differential form of the model. The angular motion, agglomeration and magnetic chain formation have been simulated, which shows that the effect of dipole-dipole interaction among powders on the orientation state becomes negligible at a high Mason number condition and at a low λ condition (the ratio of external magnetic field strength and internal magnetic moment of powder). Our developed model can be very usefully employed in the process analysis and design of magnetic powder injection molding.
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Numerical prediction of flow induced fibers orientation in injection molded polymer composites
NASA Astrophysics Data System (ADS)
Oumer, A. N.; Hamidi, N. M.; Mat Sahat, I.
2015-12-01
Since the filling stage of injection molding process has important effect on the determination of the orientation state of the fibers, accurate analysis of the flow field for the mold filling stage becomes a necessity. The aim of the paper is to characterize the flow induced orientation state of short fibers in injection molding cavities. A dog-bone shaped model is considered for the simulation and experiment. The numerical model for determination of the fibers orientation during mold-filling stage of injection molding process was solved using Computational Fluid Dynamics (CFD) software called MoldFlow. Both the simulation and experimental results showed that two different regions (or three layers of orientation structures) across the thickness of the specimen could be found: a shell region which is near to the mold cavity wall, and a core region at the middle of the cross section. The simulation results support the experimental observations that for thin plates the probability of fiber alignment to the flow direction near the mold cavity walls is high but low at the core region. It is apparent that the results of this study could assist in decisions regarding short fiber reinforced polymer composites.
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Study on In-mold Punching during PPS/GF Injection Molding
NASA Astrophysics Data System (ADS)
Inuzuka, Takayuki; Fujita, Akihiro; Nakai, Asami; Hamada, Hiroyuki
The influence of the punching condition on strength and the amount of shear droop was investigated to optimize the processing condition for punching in the mold during glass fiber reinforced polyphenylenesulfide (PPS/GF) injection molding. For in-mold punching part during cooling process, the tensile strength was constant because the pressure loss by the punch did not occur. The amount of the shear droop decreased in line with the increase in delay time because the rigidity of injection molded part in the mold increased when the resin was cooled. Moreover, when the resin temperature lowered more than the glass transition temperature, the amount of the shear droop was constant because the rigidity became constant. It is necessary to begin punching when the resin temperature lowers more than the glass transition temperature after holding pressure process is completed, to secure high strength and to assume 0.05 mm or less, at which level the shear droop cannot be visually recognized. The shortest delay time for PPS/GF is 8 sec. The delay time to minimize the amount of the shear droop can be guessed by analyzing the temperature change of the resin in the mold by injection molding CAE.
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Ultrasonically-assisted Polymer Molding: An Evaluation
NASA Astrophysics Data System (ADS)
Moles, Matthew; Roy, Anish; Silberschmidt, Vadim
Energy reduction in extrusion and injection molding processes can be achieved by the introduction of ultrasonic energy. Polymer flow can be enhanced on application of ultrasonic vibration, which can reduce the thermal and pressure input requirements to produce the same molding; higher productivity may also be achieved. In this paper, a design of an ultrasound-assisted injection mold machine is explored. An extrusion-die design was augmented with a commercial 1.5 kW ultrasonic transducer and sonotrode designed to resonate close to 20 kHz with up to 100 μm vibration amplitude. The design was evaluated with modal and thermal analysis using finite-element analysis software. The use of numerical techniques, including computational fluid dynamics, fluid-structure interaction and coupled Lagrangian-Eulerian method, to predict the effect of ultrasound on polymer flow was considered. A sonotrode design utilizing ceramic to enhance thermal isolation was also explored.
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NASA Astrophysics Data System (ADS)
Lin, Dongguo; Kang, Tae Gon; Han, Jun Sae; Park, Seong Jin; Chung, Seong Taek; Kwon, Young-Sam
2018-02-01
Both experimental and numerical analysis of powder injection molding (PIM) of Ti-6Al-4V alloy were performed to prepare a defect-free high-performance Ti-6Al-4V part with low carbon/oxygen contents. The prepared feedstock was characterized with specific experiments to identify its viscosity, pressure-volume-temperature and thermal properties to simulate its injection molding process. A finite-element-based numerical scheme was employed to simulate the thermomechanical process during the injection molding. In addition, the injection molding, debinding, sintering and hot isostatic pressing processes were performed in sequence to prepare the PIMed parts. With optimized processing conditions, the PIMed Ti-6Al-4V part exhibits excellent physical and mechanical properties, showing a final density of 99.8%, tensile strength of 973 MPa and elongation of 16%.
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NASA Astrophysics Data System (ADS)
De Jesus Vega, Marisely
Devices containing micro and nanostructured surfaces are developing and constantly finding new applications, especially for medical diagnostics, point-of-care applications, and microneedles. They are also employed in the functionalization of surfaces for superhydrophobicity, drag reduction, or reversible adhesion by mimicking bio-inspired surfaces. This research provides a thorough investigation on the effects of different polymeric materials and processing conditions on the replication of micro and nanostructured surfaces via injection molding. In addition, this dissertation also presents a novel approach for the production of durable microstructured metal tooling to be used for the production of surfaces with microchannels via injection molding. Materials such as thermoplastic vulcanizates are substituting regular thermoplastic materials and vulcanized elastomers in many applications due to their outstanding properties and ease of processability. These material properties broaden the scope of applications for microstructured surfaces. However, there is a need for understanding how these materials behave in microinjection molding since thermoplastic elastomers' behavior during injection molding have been shown to differ from that of the widely understood behavior of thermoplastics. Replication of microstructured surfaces using thermoplastic vulcanizates (TPV) was studied in the first part of this thesis. TPVs with different hardness's were molded using microinjection molding with various processing conditions and the replication and surface details of 20 microm pillars (aspect ratio of 1:1) were characterized. In the second part of this research liquid silicone rubber (LSR) was studied as a material for the production of micro and nanostructured surfaces. LSR is a silicone based material such as polydimethylsiloxane (PDMS), which is widely used for research and development of micro and nanostructured devices, and thus provides all the benefits of PDMS but can be rapidly processed via liquid injection molding. LSR with its excellent mechanical properties, transparency, non-toxicity and rapid molding capabilities can bring the production of micro and nanostructured surfaces from laboratory research facilities to high-rate manufacturing. However, previous research on microstructured surfaces made off LSR does not focus on the processing aspect of this material. Therefore, there is a lack of understanding of how different processing conditions affect the replication of microstructures. Additionally, there are no reports molding nanostructures of LSR. Features between 115 microm and 0.250 microm were molded in this work and the effect of different processing conditions and features sizes were studied. For the last part of this work, a novel metal additive manufacturing technique was used for the production of microstructured surfaces to be used as tooling for injection molding. The printing method consists of metal pastes printed through a tip onto a steel substrate. Prior work has shown spreading and swelling of features when metal pastes extrude out of the printing tip. PDMS was studied as a binder material to minimize spreading and swelling of the features by curing right after printing. In addition, prior work has shown durability of this metal printed tool up to 5000 injection molding cycles. This work compares this durability to durability of commercially available selective laser sintering metal tools. Furthermore, surface roughness was studied as this is one of the most important things to consider when molding microchannels for certain applications.
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Compound cast product and method for producing a compound cast product
Meyer, Thomas N.; Viswanathan, Srinath
2002-09-17
A compound cast product is formed in a casting mold (14) having a mold cavity (16) sized and shaped to form the cast product. A plurality of injectors (24) is supported from a bottom side (26) of the casting mold (14). The injectors (24) are in fluid communication with the mold cavity (16) through the bottom side (26) of the casting mold (14). A molten material holder furnace (12) is located beneath the casting mold (14). The holder furnace (12) defines molten material receiving chambers (36) configured to separately contain supplies of two different molten materials (37, 38). The holder furnace (12) is positioned such that the injectors (24) extend downward into the receiving chamber (36). The receiving chamber (36) is separated into at least two different flow circuits (51, 52). A first molten material (37) is received in a first flow circuit (51), and a second molten material (38) is received into a second flow circuit (52). The first and second molten materials (37, 38) are injected into the mold cavity (16) by the injectors (24) acting against the force of gravity. The injectors (24) are positioned such that the first and second molten materials (37, 38) are injected into different areas of the mold cavity (16). The molten materials (37, 38) are allowed to solidify and the resulting compound cast product is removed from the mold cavity (16).
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Integrally cored ceramic investment casting mold fabricated by ceramic stereolithography
NASA Astrophysics Data System (ADS)
Bae, Chang-Jun
Superalloy airfoils are produced by investment casting (IC), which uses ceramic cores and wax patterns with ceramic shell molds. Hollow cored superalloy airfoils in a gas turbine engine are an example of complex IC parts. The complex internal hollow cavities of the airfoil are designed to conduct cooling air through one or more passageways. These complex internal passageways have been fabricated by a lost wax process requiring several processing steps; core preparation, injection molding for wax pattern, and dipping process for ceramic shell molds. Several steps generate problems such as high cost and decreased accuracy of the ceramic mold. For example, costly tooling and production delay are required to produce mold dies for complex cores and wax patterns used in injection molding, resulting in a big obstacle for prototypes and smaller production runs. Rather than using separate cores, patterns, and shell molds, it would be advantageous to directly produce a mold that has the casting cavity and the ceramic core by one process. Ceramic stereolithography (CerSLA) can be used to directly fabricate the integrally cored ceramic casting mold (ICCM). CerSLA builds ceramic green objects from CAD files from many thin liquid layers of powder in monomer, which are solidified by polymerization with a UV laser, thereby "writing" the design for each slice. This dissertation addresses the integrally cored casting ceramic mold (ICCM), the ceramic core with a ceramic mold shell in a single patternless construction, fabricated by ceramic stereolithography (CerSLA). CerSLA is considered as an alternative method to replace lost wax processes, for small production runs or designs too complex for conventional cores and patterns. The main topic is the development of methods to successfully fabricate an ICCM by CerSLA from refractory silica, as well as related issues. The related issues are the segregation of coarse fused silica powders in a layer, the degree of segregation parameter to prevent segregation, and sintering and cristobalite transformation in fused silica compacts.
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Brittle Materials Design, High Temperature Gas Turbine
1975-04-01
was directed toward fabricating flaw- free one-piece first stage stators using a silicon metal powder injection molding composition yielding reaction...process was used because this composition utilizes thermoset polymers which cannot be handled on available injection molding equipment. Silicon...molded of several compositions incorporating slight variations. Some of the components molded had completely filled the die cavity and appeared
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Local mechanical properties of LFT injection molded parts: Numerical simulations versus experiments
NASA Astrophysics Data System (ADS)
Desplentere, F.; Soete, K.; Bonte, H.; Debrabandere, E.
2014-05-01
In predictive engineering for polymer processes, the proper prediction of material microstructure from known processing conditions and constituent material properties is a critical step forward properly predicting bulk properties in the finished composite. Operating within the context of long-fiber thermoplastics (LFT, length < 15mm) this investigation concentrates on the prediction of the local mechanical properties of an injection molded part. To realize this, the Autodesk Simulation Moldflow Insight 2014 software has been used. In this software, a fiber breakage algorithm for the polymer flow inside the mold is available. Using well known micro mechanic formulas allow to combine the local fiber length with the local orientation into local mechanical properties. Different experiments were performed using a commercially available glass fiber filled compound to compare the measured data with the numerical simulation results. In this investigation, tensile tests and 3 point bending tests are considered. To characterize the fiber length distribution of the polymer melt entering the mold (necessary for the numerical simulations), air shots were performed. For those air shots, similar homogenization conditions were used as during the injection molding tests. The fiber length distribution is characterized using automated optical method on samples for which the matrix material is burned away. Using the appropriate settings for the different experiments, good predictions of the local mechanical properties are obtained.
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Investigation of injection molding of orthogonal fluidic connector for microfluidic devices
NASA Astrophysics Data System (ADS)
Xu, Zheng; Cao, Dong; Zhao, Wei; Song, Man-cang; Liu, Jun-shan
2017-02-01
Orthogonal fluidic connections are essential for developing multilayered microfluidic devices. At present, most orthogonal connectors are realized by a horizontal channel and a vertical channel in different plates. Therefore, some extra alignment and adhesion processes for precise plate assembly are required. In this paper, the method of injection molding is proposed to make a one-body-type orthogonal connector in a single plastic plate. The connector was composed of a cantilevered tube and the other in the substrate. An injection mold was developed in which a side core-pulling mechanism and an ejection mechanism of push-pipes were combined to form the mold for an orthogonal connector. Both the type and the location of gate were optimized for the mold. The results showed that the fan gate in the middle position of the plate was the most suitable in term of both defect control and practicability. The effect of melt temperature was numerically investigated and then verified experimentally. With the optimized parameters, the relative length and the relative wall thickness of a cantilevered tube in the plastic part can reach 98.89% and 99.80%, respectively. Furthermore, using the plastic part as a cover plate, a three-layer plastic microfluidic device was conveniently fabricated for electrochemical detection.
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Hott, Morgan E; Megerian, Cliff A; Beane, Rich; Bonassar, Lawrence J
2004-07-01
The goal of the current study was to use computer-aided design and injection molding technologies to tissue engineer precisely shaped cartilage in the shape of butterfly tympanic membrane patches out of chondrocyte-seeded calcium alginate gels. Molds were designed on SolidWorks 2000 and built out of acrylonitrile butadiene styrene (ABS) using fused deposition modeling (FDM). Tympanic membrane patches were fabricated using bovine articular chondrocytes seeded at 50 x 10 cells/mL in 2% calcium alginate gels. Molded patches were cultured in vitro for up to 10 weeks and assessed biochemically, morphologically, and histologically. Unmolded patches demonstrated outstanding dimensional fidelity, with a volumetric precision of at least 3 microL, and maintained their shape well for up to 10 weeks of in vitro culture. Glycosaminoglycan and collagen content increased steadily over 10 weeks in culture, demonstrating continual deposition of new extracellular matrix consistent with new tissue development. The use of computer-aided design and injection molding technologies allows for the fabrication of very small, precisely shaped chondrocyte-seeded calcium alginate structures that faithfully maintain their shape during in vitro culture. In vitro fabrication of tympanic membrane patches with a precisely controlled geometry may have the potential to provide a minimally invasive alternative to traditional methods for the repair of chronic tympanic membrane perforations.
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40 CFR Table 8 to Subpart Wwww of... - Initial Compliance With Organic HAP Emissions Limits
Code of Federal Regulations, 2014 CFR
2014-07-01
.... open molding and centrifugal casting operations a. an organic HAP emissions limit shown in Tables 3 or... method meet the appropriate organic HAP contents. 2. open molding centrifugal casting, continuous... reduction is being claimed, are using direct die injection, and/or wet-area enclosures that meet the...
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40 CFR Table 8 to Subpart Wwww of... - Initial Compliance With Organic HAP Emissions Limits
Code of Federal Regulations, 2013 CFR
2013-07-01
.... open molding and centrifugal casting operations a. an organic HAP emissions limit shown in Tables 3 or... method meet the appropriate organic HAP contents. 2. open molding centrifugal casting, continuous... reduction is being claimed, are using direct die injection, and/or wet-area enclosures that meet the...
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40 CFR Table 8 to Subpart Wwww of... - Initial Compliance With Organic HAP Emissions Limits
Code of Federal Regulations, 2012 CFR
2012-07-01
.... open molding and centrifugal casting operations a. an organic HAP emissions limit shown in Tables 3 or... method meet the appropriate organic HAP contents. 2. open molding centrifugal casting, continuous... reduction is being claimed, are using direct die injection, and/or wet-area enclosures that meet the...
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NASA Astrophysics Data System (ADS)
Scantamburlo, Andrea; Gazzola, Luca; Sorgato, Marco; Lucchetta, Giovanni
2018-05-01
In parts manufactured by injection molding of long glass fiber reinforced polypropylene, the local fiber orientation, fiber concentration and fiber length distribution varies along both the thickness direction and the flow path. This heterogeneous microstructure significantly influences the mechanical properties variability in the molded parts. The aim of this work is to investigate the influence of the matrix viscosity, the injection speed and the mold geometry on the fiber concentration distribution. In particular, the factors involved in fiber-matrix separation and fiber pull-out during the injection phases were analyzed in order to understand the phenomenon.
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NASA Astrophysics Data System (ADS)
Kuhn, Sascha; Burr, August; Kübler, Michael; Deckert, Matthias; Bleesen, Christoph
2011-02-01
In this paper the replication qualities of periodically and randomly arranged micro-features molded in the injection molding process and their effects on surface properties are studied. The features are molded in PC, PMMA and PP at different mold wall temperatures in order to point out the necessity and profitability of a variotherm mold wall temperature control system. A one-dimensional heat conduction model is proposed to predict the cycle times of the variotherm injection molding processes. With regard to these processes, the molding results are compared to the molded surface feature heights using an atomic force microscope. In addition, the effects of the molded surface features on macroscopic surfaces are characterized in terms of light reflection using a spectrometer and in terms of water wettability by measuring the static contact angle. Furthermore, due to the sensitivity of the surface features on the molded parts, their durability is compared in a scratch test with a diamond tip. This leads to successful implementation in applications in which the optical appearance, in terms of gloss and reflection, and the water repellence, in terms of drag flow and adhesion, are of importance.
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Aslanimehr, Masoomeh; Rezvani, Shirin; Mahmoudi, Ali; Moosavi, Najmeh
2017-01-01
Statement of the Problem: Candida species are believed to play an important role in initiation and progression of denture stomatitis. The type of the denture material also influences the adhesion of candida and development of stomatitis. Purpose: The aim of this study was comparing the adherence of candida albicans to the conventional and injection molding acrylic denture base materials. Materials and Method: Twenty injection molding and 20 conventional pressure pack acrylic discs (10×10×2 mm) were prepared according to their manufacturer’s instructions. Immediately before the study, samples were placed in sterile water for 3 days to remove residual monomers. The samples were then sterilized using an ultraviolet light unit for 10 minutes. 1×108 Cfu/ml suspension of candida albicans ATCC-10231 was prepared from 48 h cultured organism on sabouraud dextrose agar plates incubated at 37oC. 100 μL of this suspension was placed on the surface of each disk. After being incubated at 37oC for 1 hour, the samples were washed with normal saline to remove non-adherent cells. Attached cells were counted using the colony count method after shaking at 3000 rmp for 20 seconds. Finally, each group was tested for 108 times and the data were statistically analyzed by t-test. Results: Quantitative analysis revealed that differences in colony count average of candida albicans adherence to conventional acrylic materials (8.3×103) comparing to injection molding acrylic resins (6×103) were statistically significant (p<0.001). Conclusion: Significant reduction of candida albicans adherence to the injection acrylic resin materials makes them valuable for patients with high risk of denture stomatitis. PMID:28280761
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Verification of a three-dimensional resin transfer molding process simulation model
NASA Technical Reports Server (NTRS)
Fingerson, John C.; Loos, Alfred C.; Dexter, H. Benson
1995-01-01
Experimental evidence was obtained to complete the verification of the parameters needed for input to a three-dimensional finite element model simulating the resin flow and cure through an orthotropic fabric preform. The material characterizations completed include resin kinetics and viscosity models, as well as preform permeability and compaction models. The steady-state and advancing front permeability measurement methods are compared. The results indicate that both methods yield similar permeabilities for a plain weave, bi-axial fiberglass fabric. Also, a method to determine principal directions and permeabilities is discussed and results are shown for a multi-axial warp knit preform. The flow of resin through a blade-stiffened preform was modeled and experiments were completed to verify the results. The predicted inlet pressure was approximately 65% of the measured value. A parametric study was performed to explain differences in measured and predicted flow front advancement and inlet pressures. Furthermore, PR-500 epoxy resin/IM7 8HS carbon fabric flat panels were fabricated by the Resin Transfer Molding process. Tests were completed utilizing both perimeter injection and center-port injection as resin inlet boundary conditions. The mold was instrumented with FDEMS sensors, pressure transducers, and thermocouples to monitor the process conditions. Results include a comparison of predicted and measured inlet pressures and flow front position. For the perimeter injection case, the measured inlet pressure and flow front results compared well to the predicted results. The results of the center-port injection case showed that the predicted inlet pressure was approximately 50% of the measured inlet pressure. Also, measured flow front position data did not agree well with the predicted results. Possible reasons for error include fiber deformation at the resin inlet and a lag in FDEMS sensor wet-out due to low mold pressures.
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Particle Image Velocimetry During Injection Molding
NASA Astrophysics Data System (ADS)
Bress, Thomas; Dowling, David
2012-11-01
Injection molding involves the unsteady non-isothermal flow of a non-Newtonian polymer melt. An optical-access mold has been used to perform particle image velocimetry (PIV) on molten polystyrene during injection molding. Velocimetry data of the mold-filling flow will be presented. Statistical assessments of the velocimetry data and scaled residuals of the continuity equation suggest that PIV can be conducted in molten plastics with an uncertainty of +/-2 percent. Simulations are often used to model polymer flow during injection molding to design molds and select processing parameters but it is difficult to determine the accuracy of these simulations due to a lack of in-mold velocimetry and melt-front progression data. Moldflow was used to simulate the filling of the optical-access mold, and these simulated results are compared to the appropriately-averaged time-varying velocity field measurements. Simulated results for melt-front progression are also compared with the experimentally observed flow fronts. The ratio of the experimentally measured average velocity magnitudes to the simulation magnitudes was found on average to be 0.99 with a standard deviation of 0.25, and the difference in velocity orientations was found to be 0.9 degree with a standard deviation of 3.2 degrees. formerly at the University of Michigan.
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Manufacturing plastic injection optical molds
NASA Astrophysics Data System (ADS)
Bourque, David
2008-08-01
ABCO Tool & Die, Inc. is a mold manufacturer specializing in the manufacturing of plastic injection molds for molded optical parts. The purpose of this presentation is to explain the concepts and procedures required to build a mold that produces precision optical parts. Optical molds can produce a variety of molded parts ranging from safety eyewear to sophisticated military lens parts, which must meet precise optical specifications. The manufacturing of these molds begins with the design engineering of precision optical components. The mold design and the related optical inserts are determined based upon the specific optical criteria and optical surface geometry. The mold manufacturing techniques will be based upon the optical surface geometry requirements and specific details. Manufacturing processes used will be specific to prescribed geometrical surface requirements of the molded part. The combined efforts result in a robust optical mold which can produce molded parts that meet the most precise optical specifications.
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Gülsoy, H Özkan; Gülsoy, Nagihan; Calışıcı, Rahmi
2014-01-01
Titanium and Titanium alloys exhibits properties that are excellent for various bio-applications. Metal injection molding is a processing route that offers reduction in costs, with the added advantage of near net-shape components. Different physical properties of Titanium alloy powders, shaped and processed via injection molding can achieve high complexity of part geometry with mechanical and bioactivity properties, similar or superior to wrought material. This study describes that the effect of particle morphology on the microstructural, mechanical and biocompatibility properties of injection molded Ti-6Al-4V (Ti64) alloy powder for biomaterials applications. Ti64 powders irregular and spherical in shape were injection molded with wax based binder. Binder debinding was performed in solvent and thermal method. After debinding the samples were sintered under high vacuum. Metallographic studies were determined to densification and the corresponding microstructural changes. Sintered samples were immersed in a simulated body fluid (SBF) with elemental concentrations that were comparable to those of human blood plasma for a total period of 15 days. Both materials were implanted in fibroblast culture for biocompatibility evaluations were carried out. The results show that spherical and irregular powder could be sintered to a maximum theoretical density. Maximum tensile strength was obtained for spherical shape powder sintered. The tensile strength of the irregular shape powder sintered at the same temperature was lower due to higher porosity. Finally, mechanical tests show that the irregular shape powder has lower mechanical properties than spherical shape powder. The sintered irregular Ti64 powder exhibited better biocompatibility than sintered spherical Ti64 powder. Results of study showed that sintered spherical and irregular Ti64 powders exhibited high mechanical properties and good biocompatibility properties.
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Microcellular nanocomposite injection molding process
Mingjun Yuan; Lih-Sheng Turng; Rick Spindler; Daniel Caulfield; Chris Hunt
2003-01-01
This study aims to explore the processing benefits and property improvements of combining nanocomposites with microcellular injection molding. The molded parts produced based on the Design of Experiments (DOE) matrices were subjected to tensile testing, impact testing, and Scanning Electron Microscope (SEM), Transmission Electron Microscope (TEM), Dynamic Mechanical...
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Modeling and flow analysis of pure nylon polymer for injection molding process
NASA Astrophysics Data System (ADS)
Nuruzzaman, D. M.; Kusaseh, N.; Basri, S.; Oumer, A. N.; Hamedon, Z.
2016-02-01
In the production of complex plastic parts, injection molding is one of the most popular industrial processes. This paper addresses the modeling and analysis of the flow process of the nylon (polyamide) polymer for injection molding process. To determine the best molding conditions, a series of simulations are carried out using Autodesk Moldflow Insight software and the processing parameters are adjusted. This mold filling commercial software simulates the cavity filling pattern along with temperature and pressure distributions in the mold cavity. In the modeling, during the plastics flow inside the mold cavity, different flow parameters such as fill time, pressure, temperature, shear rate and warp at different locations in the cavity are analyzed. Overall, this Moldflow is able to perform a relatively sophisticated analysis of the flow process of pure nylon. Thus the prediction of the filling of a mold cavity is very important and it becomes useful before a nylon plastic part to be manufactured.
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Effects of process parameters on the molding quality of the micro-needle array
NASA Astrophysics Data System (ADS)
Qiu, Z. J.; Ma, Z.; Gao, S.
2016-07-01
Micro-needle array, which is used in medical applications, is a kind of typical injection molded products with microstructures. Due to its tiny micro-features size and high aspect ratios, it is more likely to produce short shots defects, leading to poor molding quality. The injection molding process of the micro-needle array was studied in this paper to find the effects of the process parameters on the molding quality of the micro-needle array and to provide theoretical guidance for practical production of high-quality products. With the shrinkage ratio and warpage of micro needles as the evaluation indices of the molding quality, the orthogonal experiment was conducted and the analysis of variance was carried out. According to the results, the contribution rates were calculated to determine the influence of various process parameters on molding quality. The single parameter method was used to analyse the main process parameter. It was found that the contribution rate of the holding pressure on shrinkage ratio and warpage reached 83.55% and 94.71% respectively, far higher than that of the other parameters. The study revealed that the holding pressure is the main factor which affects the molding quality of micro-needle array so that it should be focused on in order to obtain plastic parts with high quality in the practical production.
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Strategies to improve electrode positioning and safety in cochlear implants.
Rebscher, S J; Heilmann, M; Bruszewski, W; Talbot, N H; Snyder, R L; Merzenich, M M
1999-03-01
An injection-molded internal supporting rib has been produced to control the flexibility of silicone rubber encapsulated electrodes designed to electrically stimulate the auditory nerve in human subjects with severe to profound hearing loss. The rib molding dies, and molds for silicone rubber encapsulation of the electrode, were designed and machined using AutoCad and MasterCam software packages in a PC environment. After molding, the prototype plastic ribs were iteratively modified based on observations of the performance of the rib/silicone composite insert in a clear plastic model of the human scala tympani cavity. The rib-based electrodes were reliably inserted farther into these models, required less insertion force and were positioned closer to the target auditory neural elements than currently available cochlear implant electrodes. With further design improvements the injection-molded rib may also function to accurately support metal stimulating contacts and wire leads during assembly to significantly increase the manufacturing efficiency of these devices. This method to reliably control the mechanical properties of miniature implantable devices with multiple electrical leads may be valuable in other areas of biomedical device design.
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Powder Injection Molding of Ceramic Engine Components for Transportation
NASA Astrophysics Data System (ADS)
Lenz, Juergen; Enneti, Ravi K.; Onbattuvelli, Valmikanathan; Kate, Kunal; Martin, Renee; Atre, Sundar
2012-03-01
Silicon nitride has been the favored material for manufacturing high-efficiency engine components for transportation due to its high temperature stability, good wear resistance, excellent corrosion resistance, thermal shock resistance, and low density. The use of silicon nitride in engine components greatly depends on the ability to fabricate near net-shape components economically. The absence of a material database for design and simulation has further restricted the engineering community in developing parts from silicon nitride. In this paper, the design and manufacturability of silicon nitride engine rotors for unmanned aerial vehicles by the injection molding process are discussed. The feedstock material property data obtained from experiments were used to simulate the flow of the material during injection molding. The areas susceptible to the formation of defects during the injection molding process of the engine component were identified from the simulations. A test sample was successfully injection molded using the feedstock and sintered to 99% density without formation of significant observable defects.
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Kraff, M C; Sanders, D R; Lieberman, H L
1983-01-01
We compared endothelial cell loss of patients implanted with lathe-cut posterior chamber lenses and those implanted with injection-molded lenses over a three-year postoperative period. Results were based on more than 2,500 measurements of corneal endothelial density. Although the technique of cataract extraction (anterior chamber phacoemulsification, posterior chamber phacoemulsification, or planned extracapsular extraction) significantly affected cell loss (P less than .01), the type of implant (lathe-cut or injection-molded) did not. Significant continuing endothelial cell loss did not occur during the first three postoperative years with injection-molded lenses. There was, however, a statistically significant 7% to 15% additional cell loss after surgery over the first two to three postoperative years with lathe-cut implants. There have been no cases of corneal endothelial decompensation developing after implantation of injection-molded or lathe-cut lenses. Because a standard field clinical specular microscope was used in this study, cell counting errors cannot be ruled out as a cause of these findings.
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NASA Astrophysics Data System (ADS)
Kameda, Takao; Sugino, Naoto; Takei, Satoshi
2016-10-01
Shear viscosity measurement device was produced to evaluate the injection molding workability for high-performance resins. Observation was possible in shear rate from 10 to 10000 [1/sec] that were higher than rotary rheometer by measuring with a plasticization cylinder of the injection molding machine. The result of measurements extrapolated result of a measurement of the rotary rheometer.
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Dimensional changes of acrylic resin denture bases: conventional versus injection-molding technique.
Gharechahi, Jafar; Asadzadeh, Nafiseh; Shahabian, Foad; Gharechahi, Maryam
2014-07-01
Acrylic resin denture bases undergo dimensional changes during polymerization. Injection molding techniques are reported to reduce these changes and thereby improve physical properties of denture bases. The aim of this study was to compare dimensional changes of specimens processed by conventional and injection-molding techniques. SR-Ivocap Triplex Hot resin was used for conventional pressure-packed and SR-Ivocap High Impact was used for injection-molding techniques. After processing, all the specimens were stored in distilled water at room temperature until measured. For dimensional accuracy evaluation, measurements were recorded at 24-hour, 48-hour and 12-day intervals using a digital caliper with an accuracy of 0.01 mm. Statistical analysis was carried out by SPSS (SPSS Inc., Chicago, IL, USA) using t-test and repeated-measures ANOVA. Statistical significance was defined at P<0.05. After each water storage period, the acrylic specimens produced by injection exhibited less dimensional changes compared to those produced by the conventional technique. Curing shrinkage was compensated by water sorption with an increase in water storage time decreasing dimensional changes. Within the limitations of this study, dimensional changes of acrylic resin specimens were influenced by the molding technique used and SR-Ivocap injection procedure exhibited higher dimensional accuracy compared to conventional molding.
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Demonstration of pharmaceutical tablet coating process by injection molding technology.
Puri, Vibha; Brancazio, David; Harinath, Eranda; Martinez, Alexander R; Desai, Parind M; Jensen, Keith D; Chun, Jung-Hoon; Braatz, Richard D; Myerson, Allan S; Trout, Bernhardt L
2018-01-15
We demonstrate the coating of tablets using an injection molding (IM) process that has advantage of being solvent free and can provide precision coat features. The selected core tablets comprising 10% w/w griseofulvin were prepared by an integrated hot melt extrusion-injection molding (HME-IM) process. Coating trials were conducted on a vertical injection mold machine. Polyethylene glycol and polyethylene oxide based hot melt extruded coat compositions were used. Tablet coating process feasibility was successfully demonstrated using different coating mold designs (with both overlapping and non-overlapping coatings at the weld) and coat thicknesses of 150 and 300 μm. The resultant coated tablets had acceptable appearance, seal at the weld, and immediate drug release profile (with an acceptable lag time). Since IM is a continuous process, this study opens opportunities to develop HME-IM continuous processes for transforming powder to coated tablets. Copyright © 2017 Elsevier B.V. All rights reserved.
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DOE Office of Scientific and Technical Information (OSTI.GOV)
Duty, Chad E; Groh, Bill
2014-10-31
ORNL collaborated with Radio Systems Corporation to investigate additive manufacturing (AM) of mold plates for plastic injection molding by direct metal deposition. The team s modelling effort identified a 100% improvement in heat transfer through use of conformal cooling lines that could be built into the mold using a revolutionary design enabled by additive manufacturing. Using the newly installed laser deposition system at the ORNL Manufacturing Demonstration Facility (MDF) a stainless steel mold core was printed.
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Brightness field distributions of microlens arrays using micro molding.
Cheng, Hsin-Chung; Huang, Chiung-Fang; Lin, Yi; Shen, Yung-Kang
2010-12-20
This study describes the brightness field distributions of microlens arrays fabricated by micro injection molding (μIM) and micro injection-compression molding (μICM). The process for fabricating microlens arrays used room-temperature imprint lithography, photoresist reflow, electroforming, μIM, μICM, and optical properties measurement. Analytical results indicate that the brightness field distribution of the molded microlens arrays generated by μICM is better than those made using μIM. Our results further demonstrate that mold temperature is the most important processing parameter for brightness field distribution of molded microlens arrays made by μIM or μICM.
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Production application of injection-molded diffractive elements
NASA Astrophysics Data System (ADS)
Clark, Peter P.; Chao, Yvonne Y.; Hines, Kevin P.
1995-12-01
We demonstrate that transmission kinoforms for visible light applications can be injection molded in acrylic in production volumes. A camera is described that employs molded Fresnel lenses to change the convergence of a projection ranging system. Kinoform surfaces are used in the projection system to achromatize the Fresnel lenses.
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NASA Astrophysics Data System (ADS)
Keey, Tony Tiew Chun; Azuddin, M.
2017-06-01
Injection molding process appears to be one of the most suitable mass and cost efficiency manufacturing processes for polymeric parts nowadays due to its high efficiency of large scale production. When down-scaling the products and components, the limits of conventional injection molding process are reached. These constraints had initiated the development of conventional injection molding process into a new era of micro injection molding technology. In this study, fiberglass reinforced polypropylenes (PP) with various glass fiber percentage materials were used. The study start with fabrication of micro tensile specimens at three different injection temperature, 260°C, 270°C and 280°C for different percentage by weight of fiberglass reinforced PP. Then evaluate the effects of various injection temperatures on the tensile properties of micro tensile specimens. Different percentage by weight of fiberglass reinforced PP were tested as well and it was found that 20% fiberglass reinforced PP possessed the greatest percentage increase of tensile strength with increasing temperatures.
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Miikkulainen, Ville; Rasilainen, Tiina; Puukilainen, Esa; Suvanto, Mika; Pakkanen, Tapani A
2008-05-06
The wetting properties of polypropylene (PP) surfaces were modified by adjusting the dimensions of the surface nanostructure. The nanostructures were generated by injection molding with nanoporous anodized aluminum oxide (AAO) as the mold insert. Atomic layer deposition (ALD) of molybdenum nitride film was used to control the pore diameters of the AAO inserts. The original 50-nm pore diameter of AAO was adjusted by depositing films of thickness 5, 10, and 15 nm on AAO. Bis(tert-butylimido)-bis(dimethylamido)molybdenum and ammonia were used as precursors in deposition. The resulting pore diameters in the nitride-coated AAO inserts were 40, 30, and 20 nm, respectively. Injection molding of PP was conducted with the coated inserts, as well as with the non-coated insert. Besides the pore diameter, the injection mold temperature was varied with temperatures of 50, 70, and 90 degrees C tested. Water contact angles of PP casts were measured and compared with theoretical contact angles calculated from Wenzel and Cassie-Baxter theories. The highest contact angle, 140 degrees , was observed for PP molded with the AAO mold insert with 30-nm pore diameter. The Cassie-Baxter theory showed better fit than the Wenzel theory to the experimental values. With the optimal AAO mask, the nanofeatures in the molded PP pieces were 100 nm high. In explanation of this finding, it is suggested that some sticking and stretching of the nanofeatures occurs during the molding. Increase in the mold temperature increased the contact angle.
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A novel tool to standardize rheology testing of molten polymers for pharmaceutical applications.
Treffer, Daniel; Troiss, Alexander; Khinast, Johannes
2015-11-10
Melt rheology provides information about material properties that are of great importance for equipment design and simulations, especially for novel pharmaceutical manufacturing operations, including extrusion, injection molding or 3d printing. To that end, homogeneous samples must be prepared, most commonly via compression or injection molding, both of which require costly equipment and might not be applicable for shear- and heat-sensitive pharmaceutical materials. Our study introduces a novel vacuum compression molding (VCM) tool for simple preparation of thermoplastic specimens using standard laboratory equipment: a hot plate and a vacuum source. Sticking is eliminated by applying polytetrafluoroethylene (PTFE) coated separation foils. The evacuation of the tool leads to compression of the sample chamber, which is cost-efficient compared to conventional methods, such as compression molding or injection molding that require special equipment. In addition, this compact design reduces the preparation time and the heat load. The VCM tool was used to prepare samples for a rheological study of three pharmaceutical polymers (Soluplus(®), Eudragit(®)E, EVA Rowalit(®) 300-1/28). The prepared samples were without any air inclusions or voids, and the measurements had a high reproducibility. All relative standard deviations were below 3%. The obtained data were fitted to the Carreau-Yasuda model and time-temperature superposition was applied. Copyright © 2015 Elsevier B.V. All rights reserved.
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Metal Injection Molding of Thin-Walled Titanium Glasses Arms: A Case Study
NASA Astrophysics Data System (ADS)
Ye, Shulong; Mo, Wei; Lv, Yonghu; Li, Xia; Kwok, Chi Tat; Yu, Peng
2018-02-01
Commercially pure titanium (CP Ti) and Ti-6Al-4V arms for a new brand of augmented reality smart glasses, which are over 170 mm in length, with thin wall structures and extremely complex surfaces, have been successfully fabricated via metal injection molding. After sintering, both the metal injection-molded (MIMed) CP Ti and Ti-6Al-4V can reach relative densities of over 95% with an oxygen content 2200 ppm, thus imparting mechanical properties comparable to cast alloys. The ductility of the MIMed CP Ti and Ti-6Al-4V are about 15% and 8%, respectively. This is a good example of applying metal injection molding to mass production of precise Ti alloy parts with complicated shapes.
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Pervez, Hifsa; Mozumder, Mohammad S; Mourad, Abdel-Hamid I
2016-08-22
The current study presents an investigation on the optimization of injection molding parameters of HDPE/TiO₂ nanocomposites using grey relational analysis with the Taguchi method. Four control factors, including filler concentration (i.e., TiO₂), barrel temperature, residence time and holding time, were chosen at three different levels of each. Mechanical properties, such as yield strength, Young's modulus and elongation, were selected as the performance targets. Nine experimental runs were carried out based on the Taguchi L₉ orthogonal array, and the data were processed according to the grey relational steps. The optimal process parameters were found based on the average responses of the grey relational grades, and the ideal operating conditions were found to be a filler concentration of 5 wt % TiO₂, a barrel temperature of 225 °C, a residence time of 30 min and a holding time of 20 s. Moreover, analysis of variance (ANOVA) has also been applied to identify the most significant factor, and the percentage of TiO₂ nanoparticles was found to have the most significant effect on the properties of the HDPE/TiO₂ nanocomposites fabricated through the injection molding process.
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Ghosh, Satyabrata; Viana, Júlio C; Reis, Rui L; Mano, João F
2008-07-01
A novel fabrication technique is proposed for the preparation of unidirectionally oriented, porous scaffolds by selective polymer leaching from lamellar structures created by conventional injection molding. The proof of the concept is implemented using a 50/50 wt.% poly(L-lactic acid)/poly(ethylene oxide) (PLLA/PEO) blend. With this composition, the PLLA and PEO blend is biphasic, containing a homogeneous PLLA/PEO phase and a PEO-rich phase. The two phases were structured using injection molding into well-defined alternating layers of homogeneous PLLA/PEO phase and PEO-rich phase. Leaching of water-soluble PEO from the PEO-rich phase produces macropores, and leaching of phase-separated PEO from the initially homogeneous PLLA/PEO phase produces micropores in the lamellae. Thus, scaffolds with a macroporous lamellar architecture with microporous walls can be produced. The lamellae are continuous along the flow direction, and a continuous lamellar thickness of less than 1 microm could be achieved. Porosities of 57-74% and pore sizes of around 50-100 microm can be obtained using this process. The tensile elastic moduli of the porous constructs were between 580 and 800 MPa. We propose that this organic-solvent-free method of preparing lamellar scaffolds with good mechanical properties, and the reproducibility associated with the injection molding technique, holds promise for a wide range of guided tissue engineering applications.
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Effect of rheological parameters on curing rate during NBR injection molding
NASA Astrophysics Data System (ADS)
Kyas, Kamil; Stanek, Michal; Manas, David; Skrobak, Adam
2013-04-01
In this work, non-isothermal injection molding process for NBR rubber mixture considering Isayev-Deng curing kinetic model, generalized Newtonian model with Carreau-WLF viscosity was modeled by using finite element method in order to understand the effect of volume flow rate, index of non-Newtonian behavior and relaxation time on the temperature profile and curing rate. It was found that for specific geometry and processing conditions, increase in relaxation time or in the index of non-Newtonian behavior increases the curing rate due to viscous dissipation taking place at the flow domain walls.
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In-line characterization of nanostructured mass-produced polymer components using scatterometry
NASA Astrophysics Data System (ADS)
Skovlund Madsen, Jonas; Højlund Thamdrup, Lasse; Czolkos, Ilja; Hansen, Poul Erik; Johansson, Alicia; Garnaes, Jørgen; Nygård, Jesper; Hannibal Madsen, Morten
2017-08-01
Scatterometry is used as an in-line metrology solution for injection molded nanostructures to evaluate the pattern replication fidelity. The method is used to give direct feedback to an operator when testing new molding parameters and for continuous quality control. A compact scatterometer has been built and tested at a fabrication facility. The scatterometry measurements, including data analysis and handling of the samples, are much faster than the injection molding cycle time, and thus, characterization does not slow down the production rate. Fabrication and characterization of 160 plastic parts with line gratings are presented here, and the optimal molding temperatures for replication of nanostructures are found for two polymers. Scatterometry results are compared to state of the art metrology solutions: atomic force and scanning electron microscopy. It is demonstrated that the scatterometer can determine the structural parameters of the samples with an accuracy of a few nanometers in less than a second, thereby enabling in-line characterization.
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Adaptive temporal refinement in injection molding
NASA Astrophysics Data System (ADS)
Karyofylli, Violeta; Schmitz, Mauritius; Hopmann, Christian; Behr, Marek
2018-05-01
Mold filling is an injection molding stage of great significance, because many defects of the plastic components (e.g. weld lines, burrs or insufficient filling) can occur during this process step. Therefore, it plays an important role in determining the quality of the produced parts. Our goal is the temporal refinement in the vicinity of the evolving melt front, in the context of 4D simplex-type space-time grids [1, 2]. This novel discretization method has an inherent flexibility to employ completely unstructured meshes with varying levels of resolution both in spatial dimensions and in the time dimension, thus allowing the use of local time-stepping during the simulations. This can lead to a higher simulation precision, while preserving calculation efficiency. A 3D benchmark case, which concerns the filling of a plate-shaped geometry, is used for verifying our numerical approach [3]. The simulation results obtained with the fully unstructured space-time discretization are compared to those obtained with the standard space-time method and to Moldflow simulation results. This example also serves for providing reliable timing measurements and the efficiency aspects of the filling simulation of complex 3D molds while applying adaptive temporal refinement.
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Properties of high density polyethylene – Paulownia wood flour composites via injection molding
USDA-ARS?s Scientific Manuscript database
Paulownia wood (PW) flour is evaluated as a bio-based fiber reinforcement. Composites of high density polyethylene (HDPE), 25% by weight of PW, and either 0% or 5% by weight of maleated polyethylene (MAPE) were produced by twin screw compounding followed by injection molding. Molded test composite...
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Foam injection molding of poly(lactic acid) with physical blowing agents
NASA Astrophysics Data System (ADS)
Pantani, R.; Sorrentino, A.; Volpe, V.; Titomanlio, G.
2014-05-01
Foam injection molding uses environmental friendly blowing agents under high pressure and temperature to produce parts having a cellular core and a compact solid skin (the so-called "structural foam"). The addition of a supercritical gas reduces the part weight and at the same time improves some physical properties of the material through the promotion of a faster crystallization; it also leads to the reduction of both the viscosity and the glass transition temperature of the polymer melt, which therefore can be injection molded adopting lower temperatures and pressures. These aspects are of extreme interest for biodegradable polymers, which often present a very narrow processing window, with the suitable processing temperatures close to the degradation conditions. In this work, foam injection molding was carried out by an instrumented molding machine, able to measure the pressure evolution in different positions along the flow-path. The material adopted was a biodegradable polymer, namely the Poly(lactic acid), PLA. The effect of a physical blowing agent (PBA) on the viscosity was measured. The density reduction and the morphology of parts obtained by different molding conditions was assessed.
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NASA Astrophysics Data System (ADS)
Bickerton, Simon
Liquid Composite Molding (LCM) encompasses a growing list of composite material manufacturing techniques. These processes have provided the promise for complex fiber reinforced plastics parts, manufactured from a single molding step. In recent years a significant research effort has been invested in development of process simulations, providing tools that have advanced current LCM technology and broadened the range of applications. The requirement for manufacture of larger, more complex parts has motivated investigation of active control of LCM processes. Due to the unlimited variety of part geometries that can be produced, finite element based process simulations will be used to some extent in design of actively controlled processes. Ongoing efforts are being made to improve material parameter specification for process simulations, increasing their value as design tools. Several phenomena occurring during mold filling have been addressed through flow visualization experimentation and analysis of manufactured composite parts. The influence of well defined air channels within a mold cavity is investigated, incorporating their effects within existing filling simulations. Three different flow configurations have been addressed, testing the application of 'equivalent permeabilities', effectively approximating air channels as representative porous media. LCM parts having doubly curved regions require preform fabrics to undergo significant, and varying deformation throughout a mold cavity. Existing methods for predicting preform deformation, and the resulting permeability distribution have been applied to a conical mold geometry. Comparisons between experiment and simulation are promising, while the geometry studied has required large deformation over much of the part, shearing the preform fabric beyond the scope of the models applied. An investigational study was performed to determine the magnitude of effect, if any, on mold filling caused by corners within LCM mold cavities. The molds applied in this study have required careful consideration of cavity thickness variations. Any effects on mold filling due to corner radii have been overshadowed by those due to preform compression. While numerical tools are available to study actively controlled mold filling in a virtual environment, some development is required for the physical equipment to implement this in practice. A versatile, multiple line fluid injection system is developed here. The equipment and control algorithms employed have provided servo control of flow rate, or injection pressure, and have been tested under very challenging conditions. The single injection line developed is expanded to a multiple line system, and shows great potential for application to actual resin systems. A case study is presented, demonstrating design and implementation of a simple actively controlled injection scheme. The experimental facility developed provides an excellent testbed for application of actively controlled mold filling concepts, an area that is providing great promise for the advancement of LCM processes.
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DOE Office of Scientific and Technical Information (OSTI.GOV)
Ameli, A.; Nofar, M.; Saniei, M.
A combination of high dielectric permittivity (ε′) and low dielectric loss (tan δ) is required for charge storage applications. In percolative systems such as conductive polymer composites, however, obtaining high ε′ and low tan δ is very challenging due to the sharp insulation-conduction transition near the threshold region. Due to the particular arrangement of conductive fillers induced by both foaming and injection molding processes, they may address this issue. Therefore, this work evaluates the application of foam injection molding process in fabricating polymer nanocomposites for energy storage. Polypropylene-multiwalled carbon nanotubes (PP-MWCNT) composites were prepared by melt mixing and foamed inmore » an injection molding process. Electrical conductivity (σ), ε′ and tan δ were then characterized. Also, scanning and transmission electron microscopy (SEM and TEM) was used to investigate the carbon nanotube’s arrangement as well as cellular morphology. The results showed that foam injection-molded composites exhibited highly superior dielectric properties to those of solid counterparts. For instance, foamed samples had ε′=68.3 and tan δ =0.05 (at 1.25 vol.% MWCNT), as opposed to ε′=17.8 and tan δ=0.04 in solid samples (at 2.56 vol.% MWCNT). The results of this work reveal that high performance dielectric nanocomposites can be developed using foam injection molding technologies for charge storage applications.« less
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Evaluation of Three Different Processing Techniques in the Fabrication of Complete Dentures.
Chintalacheruvu, Vamsi Krishna; Balraj, Rajasekaran Uttukuli; Putchala, Lavanya Sireesha; Pachalla, Sreelekha
2017-06-01
The objective of the present study is to compare the effectiveness of three different processing techniques and to find out the accuracy of processing techniques through number of occlusal interferences and increase in vertical dimension after denture processing. A cross-sectional study was conducted on a sample of 18 patients indicated for complete denture fabrication was selected for the study and they were divided into three subgroups. Three processing techniques, compression molding and injection molding using prepolymerized resin and unpolymerized resin, were used to fabricate dentures for each of the groups. After processing, laboratory-remounted dentures were evaluated for number of occlusal interferences in centric and eccentric relations and change in vertical dimension through vertical pin rise in articulator. Data were analyzed using statistical test ANOVA and SPSS software version 19.0 by IBM was used. Data obtained from three groups were subjected to one-way ANOVA test. After ANOVA test, results with significant variations were subjected to post hoc test. Number of occlusal interferences with compression molding technique was reported to be more in both centric and eccentric positions as compared to the two injection molding techniques with statistical significance in centric, protrusive, right lateral nonworking, and left lateral working positions ( P < 0.05). Mean vertical pin rise (0.52 mm) was reported to more in compression molding technique as compared to injection molding techniques, which is statistically significant ( P < 0.001). Within the limitations of this study, injection molding techniques exhibited less processing errors as compared to compression molding technique with statistical significance. There was no statistically significant difference in processing errors reported within two injection molding systems.
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DAMAGE MODELING OF INJECTION-MOLDED SHORT- AND LONG-FIBER THERMOPLASTICS
DOE Office of Scientific and Technical Information (OSTI.GOV)
Nguyen, Ba Nghiep; Kunc, Vlastimil; Bapanapalli, Satish K.
2009-10-30
This article applies the recent anisotropic rotary diffusion – reduced strain closure (ARD-RSC) model for predicting fiber orientation and a new damage model for injection-molded long-fiber thermoplastics (LFTs) to analyze progressive damage leading to total failure of injection-molded long-glass-fiber/polypropylene (PP) specimens. The ARD-RSC model was implemented in a research version of the Autodesk Moldflow Plastics Insight (MPI) processing code, and it has been used to simulate injection-molding of a long-glass-fiber/PP plaque. The damage model combines micromechanical modeling with a continuum damage mechanics description to predict the nonlinear behavior due to plasticity coupled with damage in LFTs. This model has beenmore » implemented in the ABAQUS finite element code via user-subroutines and has been used in the damage analyses of tensile specimens removed from the injection-molded long-glass-fiber/PP plaques. Experimental characterization and mechanical testing were performed to provide input data to support and validate both process modeling and damage analyses. The predictions are in agreement with the experimental results.« less
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Progress in Titanium Metal Powder Injection Molding.
German, Randall M
2013-08-20
Metal powder injection molding is a shaping technology that has achieved solid scientific underpinnings. It is from this science base that recent progress has occurred in titanium powder injection molding. Much of the progress awaited development of the required particles with specific characteristics of particle size, particle shape, and purity. The production of titanium components by injection molding is stabilized by a good understanding of how each process variable impacts density and impurity level. As summarized here, recent research has isolated the four critical success factors in titanium metal powder injection molding (Ti-MIM) that must be simultaneously satisfied-density, purity, alloying, and microstructure. The critical role of density and impurities, and the inability to remove impurities with sintering, compels attention to starting Ti-MIM with high quality alloy powders. This article addresses the four critical success factors to rationalize Ti-MIM processing conditions to the requirements for demanding applications in aerospace and medical fields. Based on extensive research, a baseline process is identified and reported here with attention to linking mechanical properties to the four critical success factors.
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Progress in Titanium Metal Powder Injection Molding
German, Randall M.
2013-01-01
Metal powder injection molding is a shaping technology that has achieved solid scientific underpinnings. It is from this science base that recent progress has occurred in titanium powder injection molding. Much of the progress awaited development of the required particles with specific characteristics of particle size, particle shape, and purity. The production of titanium components by injection molding is stabilized by a good understanding of how each process variable impacts density and impurity level. As summarized here, recent research has isolated the four critical success factors in titanium metal powder injection molding (Ti-MIM) that must be simultaneously satisfied—density, purity, alloying, and microstructure. The critical role of density and impurities, and the inability to remove impurities with sintering, compels attention to starting Ti-MIM with high quality alloy powders. This article addresses the four critical success factors to rationalize Ti-MIM processing conditions to the requirements for demanding applications in aerospace and medical fields. Based on extensive research, a baseline process is identified and reported here with attention to linking mechanical properties to the four critical success factors. PMID:28811458
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CAE for Injection Molding — Past, Present and the Future
NASA Astrophysics Data System (ADS)
Wang, Kuo K.
2004-06-01
It is well known that injection molding is the most effective process for mass-producing discrete plastic parts of complex shape to the highest precision at the lowest cost. However, due to the complex property of polymeric materials undergoing a transient non-isothermal process, it is equally well recognized that the quality of final products is often difficult to be assured. This is particularly true when a new mold or material is encountered. As a result, injection molding has often been viewed as an art than a science. During the past few decades, numerical simulation of injection molding process based on analytic models has become feasible for practical use as computers became faster and cheaper continually. A research effort was initiated at the Cornell Injection Molding Program (CIMP) in 1974 under a grant from the National Science Foundation. Over a quarter of the century, CIMP has established some scientific bases ranging from materials characterization, flow analysis, to prediction of part quality. Use of such CAE tools has become common place today in industry. Present effort has been primarily aimed at refinements of many aspects of the process. Computational efficiency and user-interface have been main thrusts by commercial software developers. Extension to 3-dimensional flow analysis for certain parts has drawn some attention. Research activities are continuing on molding of fiber-filled materials and reactive polymers. Expanded molding processes such as gas-assisted, co-injection, micro-molding and many others are continually being investigated. In the future, improvements in simulation accuracy and efficiency will continue. This will include in-depth studies on materials characterization. Intelligent on-line process control may draw more attention in order to achieve higher degree of automation. As Internet technology continues to evolve, Web-based CAE tools for design, production, remote process monitoring and control can come to path. The CAE tools will eventually be integrated into an Enterprise Resources Planning (ERP) system as the trend of enterprise globalization continues.
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Design and thermal analysis of a mold used in the injection of elastomers
NASA Astrophysics Data System (ADS)
Fekiri, Nasser; Canto, Cécile; Madec, Yannick; Mousseau, Pierre; Plot, Christophe; Sarda, Alain
2017-10-01
In the process of injection molding of elastomers, improving the energy efficiency of the tools is a current challenge for industry in terms of energy consumption, productivity and product quality. In the rubber industry, 20% of the energy consumed by capital goods comes from heating processes; more than 50% of heat losses are linked to insufficient control and thermal insulation of Molds. The design of the tooling evolves in particular towards the reduction of the heated mass and the thermal insulation of the molds. In this paper, we present a complex tool composed, on one hand, of a multi-cavity mold designed by reducing the heated mass and equipped with independent control zones placed closest to each molding cavity and, on the other hand, of a regulated channel block (RCB) which makes it possible to limit the waste of rubber during the injection. The originality of this tool lies in thermally isolating the regulated channel block from the mold and the cavities between them in order to better control the temperature field in the material which is transformed. We present the design and the instrumentation of the experimental set-up. Experimental measurements allow us to understand the thermal of the tool and to show the thermal heterogeneities on the surface of the mold and in the various cavities. Tests of injection molding of the rubber and a thermal balance on the energy consumption of the tool are carried out.
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Optimization and Simulation of Plastic Injection Process using Genetic Algorithm and Moldflow
NASA Astrophysics Data System (ADS)
Martowibowo, Sigit Yoewono; Kaswadi, Agung
2017-03-01
The use of plastic-based products is continuously increasing. The increasing demands for thinner products, lower production costs, yet higher product quality has triggered an increase in the number of research projects on plastic molding processes. An important branch of such research is focused on mold cooling system. Conventional cooling systems are most widely used because they are easy to make by using conventional machining processes. However, the non-uniform cooling processes are considered as one of their weaknesses. Apart from the conventional systems, there are also conformal cooling systems that are designed for faster and more uniform plastic mold cooling. In this study, the conformal cooling system is applied for the production of bowl-shaped product made of PP AZ564. Optimization is conducted to initiate machine setup parameters, namely, the melting temperature, injection pressure, holding pressure and holding time. The genetic algorithm method and Moldflow were used to optimize the injection process parameters at a minimum cycle time. It is found that, an optimum injection molding processes could be obtained by setting the parameters to the following values: T M = 180 °C; P inj = 20 MPa; P hold = 16 MPa and t hold = 8 s, with a cycle time of 14.11 s. Experiments using the conformal cooling system yielded an average cycle time of 14.19 s. The studied conformal cooling system yielded a volumetric shrinkage of 5.61% and the wall shear stress was found at 0.17 MPa. The difference between the cycle time obtained through simulations and experiments using the conformal cooling system was insignificant (below 1%). Thus, combining process parameters optimization and simulations by using genetic algorithm method with Moldflow can be considered as valid.
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DOE Office of Scientific and Technical Information (OSTI.GOV)
Hausnerova, Berenika; Sanetrnik, Daniel; Paravanova, Gordana
2014-05-15
The paper deals with the rheological behavior of highly filled compounds proceeded via powder injection molding (PIM) and applied in many sectors of industry (automotive, medicine, electronic or military). Online rheometer equipped with slit dies varying in surface roughness and dimensions was applied to investigate the wall-slip as a rheological phenomenon, which can be considered as a parameter indicating the separation of compound components (polymer binder and metallic powder) during high shear rates when injection molded.
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Fabrication of turbine components and properties of sintered silicon nitride
NASA Technical Reports Server (NTRS)
Neil, J. T.; French, K. W.; Quackenbush, C. L.; Smith, J. T.
1982-01-01
This paper presents a status report on the injection molding of sinterable silicon nitride at GTE Laboratories. The effort involves fabrication of single axial turbine blades and monolithic radial turbine rotors. The injection molding process is reviewed and the fabrication of the turbine components discussed. Oxidation resistance and strength results of current injection molded sintered silicon nitride as well as dimensional checks on sintered turbine blades demonstrate that this material is a viable candidate for high temperature structural applications.
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NASA Astrophysics Data System (ADS)
Hausnerova, Berenika; Sanetrnik, Daniel; Paravanova, Gordana
2014-05-01
The paper deals with the rheological behavior of highly filled compounds proceeded via powder injection molding (PIM) and applied in many sectors of industry (automotive, medicine, electronic or military). Online rheometer equipped with slit dies varying in surface roughness and dimensions was applied to investigate the wall-slip as a rheological phenomenon, which can be considered as a parameter indicating the separation of compound components (polymer binder and metallic powder) during high shear rates when injection molded.
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Comparison of glare in YAG-damaged intraocular lenses: injection-molded versus lathe-cut.
Bath, P E; Dang, Y; Martin, W H
1986-11-01
A comparative analysis of YAG laser intraocular lens (IOL) damage was undertaken on injection-molded and lathe-cut IOLs. Damage sites were evaluated with polarized light. A consistent positive polarization was observed in the damage sites of lathe-cut IOLs. A consistent negative polarization was observed in the damage sites of injection-molded IOLs. The presence of positive polarization in IOL damage sites may be correlated with increased potential for glare. Results and clinical implications are discussed.
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Design and fabrication of optical homogenizer with micro structure by injection molding process
NASA Astrophysics Data System (ADS)
Chen, C.-C. A.; Chang, S.-W.; Weng, C.-J.
2008-08-01
This paper is to design and fabricate an optical homogenizer with hybrid design of collimator, toroidal lens array, and projection lens for beam shaping of Gaussian beam into uniform cylindrical beam. TracePro software was used to design the geometry of homogenizer and simulation of injection molding was preceded by Moldflow MPI to evaluate the mold design for injection molding process. The optical homogenizer is a cylindrical part with thickness 8.03 mm and diameter 5 mm. The micro structure of toroidal array has groove height designed from 12 μm to 99 μm. An electrical injection molding machine and PMMA (n= 1.4747) were selected to perform the experiment. Experimental results show that the optics homogenizer has achieved the transfer ratio of grooves (TRG) as 88.98% and also the optical uniformity as 68% with optical efficiency as 91.88%. Future study focuses on development of an optical homogenizer for LED light source.
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NASA Astrophysics Data System (ADS)
Shieh, Jen-Yu; Wang, Luke K.; Ke, Shih-Ying
2010-07-01
A computer aided engineering (CAE) tool-assisted technique, using Moldex3D and aspheric analysis utility (AAU) software in a polycarbonate injection molding design, is proposed to manufacture large diameter aspheric plastic lenses. An experiment is conducted to verify the applicability/feasibility of the proposed technique. Using the preceding two software tools, these crucial process parameters associated with the surface profile errors and birefringence of a molded lens can be attainable. The strategy adopted here is to use the actual quantity of shrinkage after an injection molding trial of an aspherical plastic lens as a reference to perform the core shaping job while keeping the coefficients of aspheric surface, radius, and conic constant unchanged. The design philosophy is characterized by using the CAE tool as a guideline to pursue the best symmetry condition, followed by injection molding trials, to accelerate a product’s developmental time. The advantages are less design complexity and shorter developmental time for a product.
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Deflectometric analysis of high volume injection molds for production of occupational eye wear.
Speck, Alexis; Zelzer, Benedikt; Speich, Marco; Börret, Rainer; Langenbucher, Achim; Eppig, Timo
2013-12-01
Most of the protective eye wear devices currently on the market are manufactured on simple polycarbonate shields, produced by injection molding techniques. Despite high importance of optical quality, injection molds are rarely inspected for surface quality before or during the manufacturing process. Quality degradation is mainly monitored by optical testing of the molded parts. The purpose of this work was to validate a non-contact deflectometric measurement technique for surface and shape analysis of injection molds to facilitate deterministic surface quality control and to monitor minor conformity of the injection mold with the design data. The system is based on phase-measuring deflectometry with a operating measurement field of 80×80 mm(2) (±18° slope), a lateral resolution of 60μm and a local sensitivity of some nanometers. The calibration was tested with a calibration normal and a reference sphere. The results were crosschecked against a measurement of the same object with a tactile coordinate measuring machine. Eight injection molds for production of safety goggles with radii of +58mm (convex) and -60mm (concave) were measured in this study. The molds were separated into two groups (cavity 1 and 2 of the tool with different polishing techniques) and measured to test whether the measurement tool could extract differences. The analysis was performed on difference height between the measured surface and the spherical model. The device could derive the surface change due to polishing and discriminate between both polishing techniques, on the basis of the measured data. The concave nozzle sides of the first group (cavity 1) showed good shape conformity. In comparison, the nozzle sides of the second group (cavity 2) showed local deviations from design data up to 14.4μm. Local form variations of about 5μm occurred in the field of view. All convex ejector sides of both groups (cavity 1 and 2) showed rotational symmetric errors and the molds were measured in general flatter than design data. We applied a deflectometric system for measuring and evaluating specular reflective injection molding tools to optimize the production process of occupational eye wear. The surface quality could be inline monitored in the production processes for actual spectacle models. Copyright © 2013. Published by Elsevier GmbH.
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Applying simulation to optimize plastic molded optical parts
NASA Astrophysics Data System (ADS)
Jaworski, Matthew; Bakharev, Alexander; Costa, Franco; Friedl, Chris
2012-10-01
Optical injection molded parts are used in many different industries including electronics, consumer, medical and automotive due to their cost and performance advantages compared to alternative materials such as glass. The injection molding process, however, induces elastic (residual stress) and viscoelastic (flow orientation stress) deformation into the molded article which alters the material's refractive index to be anisotropic in different directions. Being able to predict and correct optical performance issues associated with birefringence early in the design phase is a huge competitive advantage. This paper reviews how to apply simulation analysis of the entire molding process to optimize manufacturability and part performance.
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DOE Office of Scientific and Technical Information (OSTI.GOV)
Nguyen, Ba Nghiep; Jin, Xiaoshi; Wang, Jin
2010-02-23
This report describes the work conducted under the Cooperative Research and Development Agreement (CRADA) (Nr. 260) between the Pacific Northwest National Laboratory (PNNL) and Autodesk, Inc. to develop and implement process models for injection-molded long-fiber thermoplastics (LFTs) in processing software packages. The structure of this report is organized as follows. After the Introduction Section (Section 1), Section 2 summarizes the current fiber orientation models developed for injection-molded short-fiber thermoplastics (SFTs). Section 3 provides an assessment of these models to determine their capabilities and limitations, and the developments needed for injection-molded LFTs. Section 4 then focuses on the development of amore » new fiber orientation model for LFTs. This model is termed the anisotropic rotary diffusion - reduced strain closure (ARD-RSC) model as it explores the concept of anisotropic rotary diffusion to capture the fiber-fiber interaction in long-fiber suspensions and uses the reduced strain closure method of Wang et al. to slow down the orientation kinetics in concentrated suspensions. In contrast to fiber orientation modeling, before this project, no standard model was developed to predict the fiber length distribution in molded fiber composites. Section 5 is therefore devoted to the development of a fiber length attrition model in the mold. Sections 6 and 7 address the implementations of the models in AMI, and the conclusions drawn from this work is presented in Section 8.« less
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NASA Astrophysics Data System (ADS)
Ries, S.; Spoerrer, A.; Altstaedt, V.
2014-05-01
Polymer foams play an important role caused by the steadily increasing demand to light weight design. In case of soft polymers, like thermoplastic elastomers (TPE), the haptic feeling of the surface is affected by the inner foam structure. Foam injection molding of TPEs leads to so called structural foam, consisting of two compact skin layers and a cellular core. The properties of soft structural foams like soft-touch, elastic and plastic behavior are affected by the resulting foam structure, e.g. thickness of the compact skins and the foam core or density. This inner structure can considerably be influenced by different processing parameters and the chosen blowing agent. This paper is focused on the selection and characterization of suitable blowing agents for foam injection molding of a TPE-blend. The aim was a high density reduction and a decent inner structure. Therefore DSC and TGA measurements were performed on different blowing agents to find out which one is appropriate for the used TPE. Moreover a new analyzing method for the description of processing characteristics by temperature dependent expansion measurements was developed. After choosing suitable blowing agents structural foams were molded with different types of blowing agents and combinations and with the breathing mold technology in order to get lower densities. The foam structure was analyzed to show the influence of the different blowing agents and combinations. Finally compression tests were performed to estimate the influence of the used blowing agent and the density reduction on the compression modulus.
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Quality Control of Injection Molded Eyewear by Non-Contact Deflectometry
NASA Astrophysics Data System (ADS)
Speck, A.; Zelzer, B.; Langenbucher, A.; Eppig, T.
2014-07-01
Occupational eye wear such as safety spectacles are manufactured by injection molding techniques. Testing of the assembled safety spectacle lenses in transmission is state of the art, but there is a lack of surface measurement systems for occupational safety lenses. The purpose of this work was to validate a deflectometric setup for topography measurement, detection of defects and visualization of the polishing quality, e.g. casting indentations or impressions, for the production process of safety spectacles. The setup is based on a customized stereo phase measuring deflectometer (PMD), equipped with 3 cameras with f'1,2 = 16 mm and f'3 = 8.5 mm and a specified measurement uncertainty of ± 3 μm. Sixteen plastic lenses and 8 corresponding injection molds from 4 parallel cavities were used for validation of the deflectometer. For comparison an interferometric method and a reference standard (< λ/10 super polished) was used. The accuracy and bias with a spherical safety spectacle sample was below 1 μm, according to DIN ISO 5725-2.2002-12. The repeatability was 2.1 μm and 35.7 μm for a blind radius fit. In conclusion, the PMD technique is an appropriate tool for characterizing occupational safety spectacle and injections mold surfaces. With the presented setup we were able to quantify the surface quality. This can be useful and may optimize the quality of the end product, in addition to standardized measuring systems in transmission.
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Real-time parameter optimization based on neural network for smart injection molding
NASA Astrophysics Data System (ADS)
Lee, H.; Liau, Y.; Ryu, K.
2018-03-01
The manufacturing industry has been facing several challenges, including sustainability, performance and quality of production. Manufacturers attempt to enhance the competitiveness of companies by implementing CPS (Cyber-Physical Systems) through the convergence of IoT(Internet of Things) and ICT(Information & Communication Technology) in the manufacturing process level. Injection molding process has a short cycle time and high productivity. This features have been making it suitable for mass production. In addition, this process is used to produce precise parts in various industry fields such as automobiles, optics and medical devices. Injection molding process has a mixture of discrete and continuous variables. In order to optimized the quality, variables that is generated in the injection molding process must be considered. Furthermore, Optimal parameter setting is time-consuming work to predict the optimum quality of the product. Since the process parameter cannot be easily corrected during the process execution. In this research, we propose a neural network based real-time process parameter optimization methodology that sets optimal process parameters by using mold data, molding machine data, and response data. This paper is expected to have academic contribution as a novel study of parameter optimization during production compare with pre - production parameter optimization in typical studies.
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Chen, Lei; Kirchberg, Stefan; Jiang, Bing-Yan; Xie, Lei; Jia, Yun-Long; Sun, Lei-Lei
2014-11-01
A uniform plano-convex spherical microlens array with a long focal length was fabricated by combining the micromilling and injection molding processes in this work. This paper presents a quantitative study of the injection molding process parameters on the uniformity of the height of the microlenses. The variation of the injection process parameters, i.e., barrel temperature, mold temperature, injection speed, and packing pressure, was found to have a significant effect on the uniformity of the height of the microlenses, especially the barrel temperature. The filling-to-packing switchover point is also critical to the uniformity of the height of the microlenses. The optimal uniformity was achieved when the polymer melts completely filled the mold cavity, or even a little excessively filled the cavity, during the filling stage. In addition, due to the filling resistance, the practical filling-to-packing switchover point can vary with the change of the filling processing conditions and lead to a non-negligible effect on the uniformity of the height of the microlenses. Furthermore, the effect of injection speed on the uniformity of the height of the microlenses was analyzed in detail. The results indicated that the effect of injection speed on the uniformity of the height of the microlenses is mainly attributed to the two functions of injection speed: transferring the filling-to-packing switchover point and affecting the distribution of residual flow stress in the polymer melt.
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Hydrogen silsesquioxane mold coatings for improved replication of nanopatterns by injection molding
NASA Astrophysics Data System (ADS)
Hobæk, Thor Christian; Matschuk, Maria; Kafka, Jan; Pranov, Henrik J.; Larsen, Niels B.
2015-03-01
We demonstrate the replication of nanosized pillars in polymer (cyclic olefin copolymer) by injection molding using nanostructured thermally cured hydrogen silsesquioxane (HSQ) ceramic coatings on stainless steel mold inserts with mold nanostructures produced by a simple embossing process. At isothermal mold conditions, the average pillar height increases by up to 100% and a more uniform height distribution is observed compared to a traditional metal mold insert. Thermal heat transfer simulations predict that the HSQ film retards the cooling of the polymer melt during the initial stages of replication, thus allowing more time to fill the nanoscale cavities compared to standard metal molds. A monolayer of a fluorinated silane (heptadecafluorotrichlorosilane) deposited on the mold surface reduces the mold/polymer interfacial energy to support demolding of the polymer replica. The mechanical stability of thermally cured HSQ makes it a promising material for nanopattern replication on an industrial scale without the need for slow and energy intensive variotherm processes.
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Pervez, Hifsa; Mozumder, Mohammad S.; Mourad, Abdel-Hamid I.
2016-01-01
The current study presents an investigation on the optimization of injection molding parameters of HDPE/TiO2 nanocomposites using grey relational analysis with the Taguchi method. Four control factors, including filler concentration (i.e., TiO2), barrel temperature, residence time and holding time, were chosen at three different levels of each. Mechanical properties, such as yield strength, Young’s modulus and elongation, were selected as the performance targets. Nine experimental runs were carried out based on the Taguchi L9 orthogonal array, and the data were processed according to the grey relational steps. The optimal process parameters were found based on the average responses of the grey relational grades, and the ideal operating conditions were found to be a filler concentration of 5 wt % TiO2, a barrel temperature of 225 °C, a residence time of 30 min and a holding time of 20 s. Moreover, analysis of variance (ANOVA) has also been applied to identify the most significant factor, and the percentage of TiO2 nanoparticles was found to have the most significant effect on the properties of the HDPE/TiO2 nanocomposites fabricated through the injection molding process. PMID:28773830
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Durability Characteristics Analysis of Plastic Worm Wheel with Glass Fiber Reinforced Polyamide.
Kim, Gun-Hee; Lee, Jeong-Won; Seo, Tae-Il
2013-05-10
Plastic worm wheel is widely used in the vehicle manufacturing field because it is favorable for weight lightening, vibration and noise reduction, as well as corrosion resistance. However, it is very difficult for general plastics to secure the mechanical properties that are required for vehicle gears. If the plastic resin is reinforced by glass fiber in the fabrication process of plastic worm wheel, it is possible to achieve the mechanical properties of metallic material levels. In this study, the mechanical characteristic analysis of the glass-reinforced plastic worm wheel, according to the contents of glass fiber, is performed by analytic and experimental methods. In the case of the glass fiber-reinforced resin, the orientation and contents of glass fibers can influence the mechanical properties. For the characteristic prediction of plastic worm wheel, computer-aided engineering (CAE) analysis processes such as structural and injection molding analysis were executed with the polyamide resin reinforcement glass fiber (25 wt %, 50 wt %). The injection mold for fabricating the prototype plastic worm wheel was designed and made to reflect the CAE analysis results. Finally, the durability of prototype plastic worm wheel fabricated by the injection molding process was evaluated by the experimental method and the characteristics according to the glass fiber contents.
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Durability Characteristics Analysis of Plastic Worm Wheel with Glass Fiber Reinforced Polyamide
Kim, Gun-Hee; Lee, Jeong-Won; Seo, Tae-Il
2013-01-01
Plastic worm wheel is widely used in the vehicle manufacturing field because it is favorable for weight lightening, vibration and noise reduction, as well as corrosion resistance. However, it is very difficult for general plastics to secure the mechanical properties that are required for vehicle gears. If the plastic resin is reinforced by glass fiber in the fabrication process of plastic worm wheel, it is possible to achieve the mechanical properties of metallic material levels. In this study, the mechanical characteristic analysis of the glass-reinforced plastic worm wheel, according to the contents of glass fiber, is performed by analytic and experimental methods. In the case of the glass fiber-reinforced resin, the orientation and contents of glass fibers can influence the mechanical properties. For the characteristic prediction of plastic worm wheel, computer-aided engineering (CAE) analysis processes such as structural and injection molding analysis were executed with the polyamide resin reinforcement glass fiber (25 wt %, 50 wt %). The injection mold for fabricating the prototype plastic worm wheel was designed and made to reflect the CAE analysis results. Finally, the durability of prototype plastic worm wheel fabricated by the injection molding process was evaluated by the experimental method and the characteristics according to the glass fiber contents. PMID:28809248
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All plastic ultra-small size imaging lens unit fabrication and evaluation for endoscope
NASA Astrophysics Data System (ADS)
Ishii, Kenta; Okamoto, Dai; Ushio, Makoto; Tai, Hidetoshi; Nishihara, Atsuhiko; Tokuda, Kimio; Kawai, Shinsuke; Kitagawa, Seiichiro
2017-02-01
There is demand for small-size lens units for endoscope and industrial applications. Polished glass lenses with a diameter of 1 - 2mm exist, however plastic lenses similar in size are not commonplace. For low-cost, light-weight, and mass production, plastic lens fabrication is extremely beneficial. Especially, in the medical field, there is strong demand for disposable lens unit for endoscopes which prevent contamination due to reuse of the lens. Therefore, high mass producible and low cost becomes increasingly important. This paper reports our findings on injection-molded ultra-small size plastic lens units with a diameter of 1.3mm and total thickness of 1.4mm. We performed optical design, injection molding, and lens unit assembly for injection moldable, high imaging performance ultra-small sized lens units. We prioritize a robust product design, considering injection molding properties and lens unit assembly, with feedback from molding simulations reflected into the optical design. A mold capable of high precision lens positioning is used to fabricate the lenses and decrease the variability of the assembly. The geometric dimensions of the resulting lenses, are measured and used in the optical simulation to validate the optical performance, and a high agreement is reported. The injection molding of the lens and the assembly of the lens unit is performed with high precision, and results in high optical performance.
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Study of the injection molding of a polarizing beam splitter.
Jose de Carvalho, Edson; Braga, Edmundo da Silva; Cescato, Lucila H
2006-01-01
We describe the replication of a relief grating that behaves like a polarizing beam splitter by injection molding. Measurements of the grating master, nickel shim, and replica, performed by atomic force microscopy, allow establishing a limit for the injection molding technique (currently used in CD fabrication) to aspect ratios of approximately 0.15. Although this limit strongly reduces the diffraction efficiency of the elements as well as their polarizing properties, extinction ratios of approximately 10:1 were measured for the replicas in a large range of wavelengths.
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FIBER ORIENTATION IN INJECTION MOLDED LONG CARBON FIBER THERMOPLASTIC COMPOSITES
DOE Office of Scientific and Technical Information (OSTI.GOV)
Wang, Jin; Nguyen, Ba Nghiep; Mathur, Raj N.
2015-03-23
A set of edge-gated and center-gated plaques were injection molded with long carbon fiber-reinforced thermoplastic composites, and the fiber orientation was measured at different locations of the plaques. Autodesk Simulation Moldflow Insight (ASMI) software was used to simulate the injection molding of these plaques and to predict the fiber orientation, using the anisotropic rotary diffusion and the reduced strain closure models. The phenomenological parameters of the orientation models were carefully identified by fitting to the measured orientation data. The fiber orientation predictions show very good agreement with the experimental data.
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Use of acrylic sheet molds for elastomeric products
NASA Technical Reports Server (NTRS)
Heisman, R. M.; Koerner, A. E.; Messineo, S. M.
1970-01-01
Molds constructed of acrylic sheet are more easily machined than metal, are transparent to ensure complete filling during injection, and have smooth surfaces free of contamination. Technique eliminates flashing on molded parts and mold release agents.
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de Melo, Liliane Pimenta; Salmoria, Gean Vitor; Fancello, Eduardo Alberto; Roesler, Carlos Rodrigo de Mello
2017-01-01
The purpose of this article is to present mechanical and physicochemical properties during in vitro degradation of PLGA material as craniofacial plates based on different values of injection molded temperatures. Injection molded plates were submitted to in vitro degradation in a thermostat bath at 37 ± 1°C by 16 weeks. The material was removed after 15, 30, 60, and 120 days; then bending stiffness, crystallinity, molecular weights, and viscoelasticity were studied. A significant decrease of molecular weight and mechanical properties over time and a difference in FT-IR after 60 days showed faster degradation of the material in the geometry studied. DSC analysis confirmed that the crystallization occurred, especially in higher melt temperature condition. DMA analysis suggests a greater contribution of the viscous component of higher temperature than lower temperature in thermomechanical behavior. The results suggest that physical-mechanical properties of PLGA plates among degradation differ per injection molding temperatures.
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Bio-inspired piezoelectric artificial hair cell sensor fabricated by powder injection molding
NASA Astrophysics Data System (ADS)
Han, Jun Sae; Oh, Keun Ha; Moon, Won Kyu; Kim, Kyungseop; Joh, Cheeyoung; Seo, Hee Seon; Bollina, Ravi; Park, Seong Jin
2015-12-01
A piezoelectric artificial hair cell sensor was fabricated by the powder injection molding process in order to make an acoustic vector hydrophone. The entire process of powder injection molding was developed and optimized for PMN-PZT ceramic powder. The artificial hair cell sensor, which consists of high aspect ratio hair cell and three rectangular mechanoreceptors, was precisely fabricated through the developed powder injection molding process. The density and the dielectric property of the fabricated sensor shows 98% of the theoretical density and 85% of reference dielectric property of PMN-PZT ceramic powder. With regard to homogeneity, three rectangular mechanoreceptors have the same dimensions, with 3 μm of tolerance with 8% of deviation of dielectric property. Packaged vector hydrophones measure the underwater acoustic signals from 500 to 800 Hz with -212 dB of sensitivity. Directivity of vector hydrophone was acquired at 600 Hz as analyzing phase differences of electric signals.
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Aslanimehr, Masoomeh; Rezvani, Shirin; Mahmoudi, Ali; Moosavi, Najmeh
2017-03-01
Candida species are believed to play an important role in initiation and progression of denture stomatitis. The type of the denture material also influences the adhesion of candida and development of stomatitis. The aim of this study was comparing the adherence of candida albicans to the conventional and injection molding acrylic denture base materials. Twenty injection molding and 20 conventional pressure pack acrylic discs (10×10×2 mm) were prepared according to their manufacturer's instructions. Immediately before the study, samples were placed in sterile water for 3 days to remove residual monomers. The samples were then sterilized using an ultraviolet light unit for 10 minutes. 1×10 8 Cfu/ml suspension of candida albicans ATCC-10231 was prepared from 48 h cultured organism on sabouraud dextrose agar plates incubated at 37oC. 100 μL of this suspension was placed on the surface of each disk. After being incubated at 37oC for 1 hour, the samples were washed with normal saline to remove non-adherent cells. Attached cells were counted using the colony count method after shaking at 3000 rmp for 20 seconds. Finally, each group was tested for 108 times and the data were statistically analyzed by t-test. Quantitative analysis revealed that differences in colony count average of candida albicans adherence to conventional acrylic materials (8.3×10 3 ) comparing to injection molding acrylic resins (6×10 3 ) were statistically significant ( p <0.001). Significant reduction of candida albicans adherence to the injection acrylic resin materials makes them valuable for patients with high risk of denture stomatitis.
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Injection molding lens metrology using software configurable optical test system
NASA Astrophysics Data System (ADS)
Zhan, Cheng; Cheng, Dewen; Wang, Shanshan; Wang, Yongtian
2016-10-01
Optical plastic lens produced by injection molding machine possesses numerous advantages of light quality, impact resistance, low cost, etc. The measuring methods in the optical shop are mainly interferometry, profile meter. However, these instruments are not only expensive, but also difficult to alignment. The software configurable optical test system (SCOTS) is based on the geometry of the fringe refection and phase measuring deflectometry method (PMD), which can be used to measure large diameter mirror, aspheric and freeform surface rapidly, robustly, and accurately. In addition to the conventional phase shifting method, we propose another data collection method called as dots matrix projection. We also use the Zernike polynomials to correct the camera distortion. This polynomials fitting mapping distortion method has not only simple operation, but also high conversion precision. We simulate this test system to measure the concave surface using CODE V and MATLAB. The simulation results show that the dots matrix projection method has high accuracy and SCOTS has important significance for on-line detection in optical shop.
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NASA Astrophysics Data System (ADS)
Fang, Jun
Thermotropic liquid crystalline polymers (TLCPs) are a class of promising engineering materials for high-demanding structural applications. Their excellent mechanical properties are highly correlated to the underlying molecular orientation states, which may be affected by complex flow fields during melt processing. Thus, understanding and eventually predicting how processing flows impact molecular orientation is a critical step towards rational design work in order to achieve favorable, balanced physical properties in finished products. This thesis aims to develop deeper understanding of orientation development in commercial TLCPs during processing by coordinating extensive experimental measurements with numerical computations. In situ measurements of orientation development of LCPs during processing are a focal point of this thesis. An x-ray capable injection molding apparatus is enhanced and utilized for time-resolved measurements of orientation development in multiple commercial TLCPs during injection molding. Ex situ wide angle x-ray scattering is also employed for more thorough characterization of molecular orientation distributions in molded plaques. Incompletely injection molded plaques ("short shots") are studied to gain further insights into the intermediate orientation states during mold filling. Finally, two surface orientation characterization techniques, near edge x-ray absorption fine structure (NEXAFS) and infrared attenuated total reflectance (FTIR-ATR) are combined to investigate the surface orientation distribution of injection molded plaques. Surface orientation states are found to be vastly different from their bulk counterparts due to different kinematics involved in mold filling. In general, complex distributions of orientation in molded plaques reflect the spatially varying competition between shear and extension during mold filling. To complement these experimental measurements, numerical calculations based on the Larson-Doi polydomain model are performed. The implementation of the Larson-Doi in complex processing flows is performed using a commercial process modeling software suite (MOLDFLOWRTM), exploiting a nearly exact analogy between the Larson-Doi model and a fiber orientation model that has been widely used in composites processing simulations. The modeling scheme is first verified by predicting many qualitative and quantitative features of molecular orientation distributions in isothermal extrusion-fed channel flows. In coordination with experiments, the model predictions are found to capture many qualitative features observed in injection molded plaques (including short shots). The final, stringent test of Larson-Doi model performance is prediction of in situ transient orientation data collected during mold filling. The model yields satisfactory results, though certain numerical approximations limit performance near the mold front.
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Modeling injection molding of net-shape active ceramic components.
DOE Office of Scientific and Technical Information (OSTI.GOV)
Baer, Tomas; Cote, Raymond O.; Grillet, Anne Mary
2006-11-01
To reduce costs and hazardous wastes associated with the production of lead-based active ceramic components, an injection molding process is being investigated to replace the current machining process. Here, lead zirconate titanate (PZT) ceramic particles are suspended in a thermoplastic resin and are injected into a mold and allowed to cool. The part is then bisque fired and sintered to complete the densification process. To help design this new process we use a finite element model to describe the injection molding of the ceramic paste. Flow solutions are obtained using a coupled, finite-element based, Newton-Raphson numerical method based on themore » GOMA/ARIA suite of Sandia flow solvers. The evolution of the free surface is solved with an advanced level set algorithm. This approach incorporates novel methods for representing surface tension and wetting forces that affect the evolution of the free surface. Thermal, rheological, and wetting properties of the PZT paste are measured for use as input to the model. The viscosity of the PZT is highly dependent both on temperature and shear rate. One challenge in modeling the injection process is coming up with appropriate constitutive equations that capture relevant phenomenology without being too computationally complex. For this reason we model the material as a Carreau fluid and a WLF temperature dependence. Two-dimensional (2D) modeling is performed to explore the effects of the shear in isothermal conditions. Results indicate that very low viscosity regions exist near walls and that these results look similar in terms of meniscus shape and fill times to a simple Newtonian constitutive equation at the shear-thinned viscosity for the paste. These results allow us to pick a representative viscosity to use in fully three-dimensional (3D) simulation, which because of numerical complexities are restricted to using a Newtonian constitutive equation. Further 2D modeling at nonisothermal conditions shows that the choice of representative Newtonian viscosity is dependent on the amount of heating of the initially room temperature mold. An early 3D transient model shows that the initial design of the distributor is sub-optimal. However, these simulations take several months to run on 4 processors of an HP workstation using a preconditioner/solver combination of ILUT/GMRES with fill factors of 3 and PSPG stabilization. Therefore, several modifications to the distributor geometry and orientations of the vents and molds have been investigated using much faster 3D steady-state simulations. The pressure distribution for these steady-state calculations is examined for three different distributor designs to see if this can indicate which geometry has the superior design. The second modification, with a longer distributor, is shown to have flatter, more monotonic isobars perpendicular to the flow direction indicating a better filling process. The effects of the distributor modifications, as well as effects of the mold orientation, have also been examined with laboratory experiments in which the flow of a viscous Newtonian oil entering transparent molds is recorded visually. Here, the flow front is flatter and voids are reduced for the second geometry compared to the original geometry. A horizontal orientation, as opposed to the planned vertical orientation, results in fewer voids. Recently, the Navier-Stokes equations have been stabilized with the Dohrman-Bochev PSPP stabilization method, allowing us to calculate transient 3D simulations with computational times on the order of days instead of months. Validation simulations are performed and compared to the experiments. Many of the trends of the experiments are captured by the level set modeling, though quantitative agreement is lacking mainly due to the high value of the gas phase viscosity necessary for numerical stability, though physically unrealistic. More correct trends are predicted for the vertical model than the horizontal model, which is serendipitous as the actual mold is held in a vertical geometry. The full, transient mold filling calculations indicate that the flow front is flatter and voids may be reduced for the second geometry compared to the original geometry. The validated model is used to predict mold filling for the actual process with the material properties for the PZT paste, the original distributor geometry, and the mold in a vertical orientation. This calculation shows that voids may be trapped at the four corners of the mold opposite the distributor.« less
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A Model for Fiber Length Attrition in Injection-Molded Long-Fiber Composites
DOE Office of Scientific and Technical Information (OSTI.GOV)
TuckerIII, Charles L.; Phelps, Jay H; El-Rahman, Ahmed Abd
2013-01-01
Long-fiber thermoplastic (LFT) composites consist of an engineering thermoplastic matrix with glass or carbon reinforcing fibers that are initially 10 to 13 mm long. When an LFT is injection molded, flow during mold filling orients the fibers and degrades the fiber length. Fiber orientation models for injection molding are well developed, and special orientation models for LFTs have been developed. Here we present a detailed quantitative model for fiber length attrition in a flowing fiber suspension. The model tracks a discrete fiber length distribution (FLD) at each spatial node. Key equations are a conservation equation for total fiber length, andmore » a breakage rate equation. The breakage rate is based on buckling of fibers due to hydrodynamic forces, when the fibers are in unfavorable orientations. The FLD model is combined with a mold filling simulation to predict spatial and temporal variations in fiber length distribution in a mold cavity during filling. The predictions compare well to experiments on a glassfiber/ PP LFT molding. Fiber length distributions predicted by the model are easily incorporated into micromechanics models to predict the stress-strain behavior of molded LFT materials. Author to whom correspondence should be addressed; electronic mail: ctucker@illinois.edu 1« less
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Characterization of curing behavior of UV-curable LSR for LED embedded injection mold
NASA Astrophysics Data System (ADS)
Tae, Joon-Sung; Yim, Kyung-Gyu; Rhee, Byung-Ohk; Kwak, Jae B.
2016-11-01
For many applications, liquid silicone rubber (LSR) injection molding is widely used for their great design flexibility and high productivity. In particular, a sealing part for a mobile device such as smartphone and watch has been produced by injection molding. While thermally curable LSR causes deformation problem due to a high mold temperature, UV-curable LSR can be molded at room temperature, which has advantages for over-molding with inserts of temperature-sensitive materials. Ultraviolet light-emitting diodes (UV LEDs) have advantages such as a longer service life, a lower heat dissipation, and smaller size to equip into the mold than conventional halogen or mercury UV lamps. In this work, rheological behavior of UV-curable LSR during curing process was analyzed by UV LEDs available in the market. UV-LEDs of various wave lengths and intensities were tested. The steady shear test was applied to find the starting time of curing and the SAOS was applied to find the ending time of curing to estimate processing time. In addition, the hardness change with irradiation energy was compared with the rheological data to confirm the reliability of the rheological test.
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Shin, Kwangho; Heo, Youngmoo; Park, Hyungpil; Chang, Sungho; Rhee, Byungohk
2013-12-12
In this study, we focus on making a double-sided metal plate with an internal structure, such as honeycomb. The stainless steel powder was used in the metal injection molding (MIM) process. The preliminary studies were carried out for the measurement of the viscosity of the stainless steel feedstock and for the prediction of the filling behavior through Computer Aided Engineering (CAE) simulation. PE (high density polyethylene (HDPE) and low density polyethylene (LDPE)) and polypropylene (PP) resins were used to make the sacrificed insert with a honeycomb structure using a plastic injection molding process. Additionally, these sacrificed insert parts were inserted in the metal injection mold, and the metal injection molding process was carried out to build a green part with rectangular shape. Subsequently, debinding and sintering processes were adopted to remove the sacrificed polymer insert. The insert had a suitable rigidity that was able to endure the filling pressure. The core shift analysis was conducted to predict the deformation of the insert part. The 17-4PH feedstock with a low melting temperature was applied. The glass transition temperature of the sacrificed polymer insert would be of a high grade, and this insert should be maintained during the MIM process. Through these processes, a square metal plate with a honeycomb structure was made.
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Shin, Kwangho; Heo, Youngmoo; Park, Hyungpil; Chang, Sungho; Rhee, Byungohk
2013-01-01
In this study, we focus on making a double-sided metal plate with an internal structure, such as honeycomb. The stainless steel powder was used in the metal injection molding (MIM) process. The preliminary studies were carried out for the measurement of the viscosity of the stainless steel feedstock and for the prediction of the filling behavior through Computer Aided Engineering (CAE) simulation. PE (high density polyethylene (HDPE) and low density polyethylene (LDPE)) and polypropylene (PP) resins were used to make the sacrificed insert with a honeycomb structure using a plastic injection molding process. Additionally, these sacrificed insert parts were inserted in the metal injection mold, and the metal injection molding process was carried out to build a green part with rectangular shape. Subsequently, debinding and sintering processes were adopted to remove the sacrificed polymer insert. The insert had a suitable rigidity that was able to endure the filling pressure. The core shift analysis was conducted to predict the deformation of the insert part. The 17-4PH feedstock with a low melting temperature was applied. The glass transition temperature of the sacrificed polymer insert would be of a high grade, and this insert should be maintained during the MIM process. Through these processes, a square metal plate with a honeycomb structure was made. PMID:28788427
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DOE Office of Scientific and Technical Information (OSTI.GOV)
Özgün, Özgür, E-mail: oozgun@bingol.edu.tr; Yılmaz, Ramazan; Özkan Gülsoy, H.
In this study, the effect of aging heat treatment on fracture toughness and impact strength of Ni-625 superalloy fabricated by using powder injection molding (PIM) method was examined. After a feedstock was prepared by mixing the prealloyed Ni-625 superalloy powder, which was fabricated by gas atomisation, with a polymeric binder system and then it was granulated, it was shaped through the use of injection. The molded specimens were sintered at 1300 °C for 3 h after a two-stage debinding process. Once the sintered specimens were treated in the solution at 1150 °C for 2 h, they were quenched. Aging treatmentmore » was performed by keeping specimens at 745 °C for 22 h. Fracture toughness and impact tests were performed on sintered and aged specimens. Microstructure examinations were performed by using optical microscope, scanning electron microscope, and transmission electron microscope. The results revealed that aging heat treatment led to the formation of some carbides and intermetallic phases in the microstructure. While the hardness of the aged specimens increased due to these phases, their fracture toughness and impact strength values decreased. - Highlights: • Ni-625 superalloy components were produced by means of powder injection molding. • The produced components were subjected to aging treatment. • Aging process provided approximately 50% increase in the hardness of components. • Intermetallic precipitates, carbides and TCP phases occurred within the aged parts. • Fracture toughness and impact strength values decreased due to the hard phases.« less
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Gaaz, Tayser Sumer; Sulong, Abu Bakar; Kadhum, Abdul Amir H.; Nassir, Mohamed H.; Al-Amiery, Ahmed A.
2016-01-01
Halloysite nanotubes-thermoplastic polyurethane (HNTs-TPU) nanocomposites are attractive products due to increasing demands for specialized materials. This study attempts to optimize the parameters for injection just before marketing. The study shows the importance of the preparation of the samples and how well these parameters play their roles in the injection. The control parameters for injection are carefully determined to examine the mechanical properties and the density of the HNTs-TPU nanocomposites. Three types of modified HNTs were used as untreated HNTs (uHNTs), sulfuric acid treated (aHNTs) and a combined treatment of polyvinyl alcohol (PVA)-sodium dodecyl sulfate (SDS)-malonic acid (MA) (treatment (mHNTs)). It was found that mHNTs have the most influential effect of producing HNTs-TPU nanocomposites with the best qualities. One possible reason for this extraordinary result is the effect of SDS as a disperser and MA as a crosslinker between HNTs and PVA. For the highest tensile strength, the control parameters are demonstrated at 150 °C (injection temperature), 8 bar (injection pressure), 30 °C (mold temperature), 8 min (injection time), 2 wt % (HNTs loading) and mHNT (HNTs type). Meanwhile, the optimized combination of the levels for all six control parameters that provide the highest Young’s modulus and highest density was found to be 150 °C (injection temperature), 8 bar (injection pressure), 32 °C (mold temperature), 8 min (injection time), 3 wt % (HNTs loading) and mHNT (HNTs type). For the best tensile strain, the six control parameters are found to be 160 °C (injection temperature), 8 bar (injection pressure), 32 °C (mold temperature), 8 min (injection time), 2 wt % (HNTs loading) and mHNT (HNTs type). For the highest hardness, the best parameters are 140 °C (injection temperature), 6 bar (injection pressure), 30 °C (mold temperature), 8 min (injection time), 2 wt % (HNTs loading) and mHNT (HNTs type). The analyses are carried out by coordinating Taguchi and ANOVA approaches. Seemingly, mHNTs has shown its very important role in the resulting product. PMID:28774069
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Gaaz, Tayser Sumer; Sulong, Abu Bakar; Kadhum, Abdul Amir H; Nassir, Mohamed H; Al-Amiery, Ahmed A
2016-11-22
Halloysite nanotubes-thermoplastic polyurethane (HNTs-TPU) nanocomposites are attractive products due to increasing demands for specialized materials. This study attempts to optimize the parameters for injection just before marketing. The study shows the importance of the preparation of the samples and how well these parameters play their roles in the injection. The control parameters for injection are carefully determined to examine the mechanical properties and the density of the HNTs-TPU nanocomposites. Three types of modified HNTs were used as untreated HNTs ( u HNTs), sulfuric acid treated ( a HNTs) and a combined treatment of polyvinyl alcohol (PVA)-sodium dodecyl sulfate (SDS)-malonic acid (MA) (treatment ( m HNTs)). It was found that m HNTs have the most influential effect of producing HNTs-TPU nanocomposites with the best qualities. One possible reason for this extraordinary result is the effect of SDS as a disperser and MA as a crosslinker between HNTs and PVA. For the highest tensile strength, the control parameters are demonstrated at 150 °C (injection temperature), 8 bar (injection pressure), 30 °C (mold temperature), 8 min (injection time), 2 wt % (HNTs loading) and m HNT (HNTs type). Meanwhile, the optimized combination of the levels for all six control parameters that provide the highest Young's modulus and highest density was found to be 150 °C (injection temperature), 8 bar (injection pressure), 32 °C (mold temperature), 8 min (injection time), 3 wt % (HNTs loading) and m HNT (HNTs type). For the best tensile strain, the six control parameters are found to be 160 °C (injection temperature), 8 bar (injection pressure), 32 °C (mold temperature), 8 min (injection time), 2 wt % (HNTs loading) and m HNT (HNTs type). For the highest hardness, the best parameters are 140 °C (injection temperature), 6 bar (injection pressure), 30 °C (mold temperature), 8 min (injection time), 2 wt % (HNTs loading) and m HNT (HNTs type). The analyses are carried out by coordinating Taguchi and ANOVA approaches. Seemingly, m HNTs has shown its very important role in the resulting product.
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DOE Office of Scientific and Technical Information (OSTI.GOV)
Nguyen, Ba Nghiep; Jin, Xiaoshi; Wang, Jin
2012-02-23
This report describes the work conducted under the CRADA Nr. PNNL/304 between Battelle PNNL and Autodesk whose objective is to validate the new process models developed under the previous CRADA for large injection-molded LFT composite structures. To this end, the ARD-RSC and fiber length attrition models implemented in the 2013 research version of Moldflow was used to simulate the injection molding of 600-mm x 600-mm x 3-mm plaques from 40% glass/polypropylene (Dow Chemical DLGF9411.00) and 40% glass/polyamide 6,6 (DuPont Zytel 75LG40HSL BK031) materials. The injection molding was performed by Injection Technologies, Inc. at Windsor, Ontario (under a subcontract by Oakmore » Ridge National Laboratory, ORNL) using the mold offered by the Automotive Composite Consortium (ACC). Two fill speeds under the same back pressure were used to produce plaques under slow-fill and fast-fill conditions. Also, two gating options were used to achieve the following desired flow patterns: flows in edge-gated plaques and in center-gated plaques. After molding, ORNL performed measurements of fiber orientation and length distributions for process model validations. The structure of this report is as follows. After the Introduction (Section 1), Section 2 provides a summary of the ARD-RSC and fiber length attrition models. A summary of model implementations in the latest research version of Moldflow is given in Section 3. Section 4 provides the key processing conditions and parameters for molding of the ACC plaques. The validations of the ARD-RSC and fiber length attrition models are presented and discussed in Section 5. The conclusions will be drawn in Section 6.« less
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Development of fire resistant, nontoxic aircraft interior materials
NASA Technical Reports Server (NTRS)
Haley, G.; Silverman, B.; Tajima, Y.
1976-01-01
All available newly developed nonmetallic polymers were examined for possible usage in developing fire resistant, nontoxic nonmetallic parts or assemblies for aircraft interiors. Specifically, feasibility for the development of clear films for new decorative laminates, compression moldings, injection molded parts, thermoformed plastic parts, and flexible foams were given primary considerations. Preliminary data on the flame resistant characteristics of the materials were obtained. Preliminary toxicity data were generated from samples of materials submitted from the contractor. Preliminary data on the physical characteristics of various thermoplastic materials to be considered for either compression molded, injection molded, or thermoformed parts were obtained.
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DOE Office of Scientific and Technical Information (OSTI.GOV)
Thi, Thanh Binh Nguyen; Morioka, Mizuki; Yokoyama, Atsushi
Numerical prediction of the fiber orientation in the short-glass fiber (GF) reinforced polyamide 6 (PA6) composites with the fiber weight concentration of 30%, 50%, and 70% manufactured by the injection molding process is presented. And the fiber orientation was also directly observed and measured through X-ray computed tomography. During the injection molding process of the short-fiber/thermoplastic composite, the fiber orientation is produced by the flow states and the fiber-fiber interaction. Folgar and Tucker equation is the well known for modeling the fiber orientation in a concentrated suspension. They included into Jeffrey’s equation a diffusive type of term by introducing amore » phenomenological coefficient to account for the fiber-fiber interaction. Our developed model for the fiber-fiber interaction was proposed by modifying the rotary diffusion term of the Folgar-Tucker equation. This model was presented in a conference paper of the 29{sup th} International Conference of the Polymer Processing Society published by AIP conference proceeding. For modeling fiber interaction, the fiber dynamic simulation was introduced in order to obtain a global fiber interaction coefficient, which is sum function of the fiber concentration, aspect ratio, and angular velocity. The fiber orientation is predicted by using the proposed fiber interaction model incorporated into a computer aided engineering simulation package C-Mold. An experimental program has been carried out in which the fiber orientation distribution has been measured in 100 x 100 x 2 mm injection-molded plate and 100 x 80 x 2 mm injection-molded weld by analyzed with a high resolution 3D X-ray computed tomography system XVA-160α, and calculated by X-ray computed tomography imaging. The numerical prediction shows a good agreement with experimental validation. And the complex fiber orientation in the injection-molded weld was investigated.« less
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NASA Astrophysics Data System (ADS)
Thi, Thanh Binh Nguyen; Morioka, Mizuki; Yokoyama, Atsushi; Hamanaka, Senji; Yamashita, Katsuhisa; Nonomura, Chisato
2015-05-01
Numerical prediction of the fiber orientation in the short-glass fiber (GF) reinforced polyamide 6 (PA6) composites with the fiber weight concentration of 30%, 50%, and 70% manufactured by the injection molding process is presented. And the fiber orientation was also directly observed and measured through X-ray computed tomography. During the injection molding process of the short-fiber/thermoplastic composite, the fiber orientation is produced by the flow states and the fiber-fiber interaction. Folgar and Tucker equation is the well known for modeling the fiber orientation in a concentrated suspension. They included into Jeffrey's equation a diffusive type of term by introducing a phenomenological coefficient to account for the fiber-fiber interaction. Our developed model for the fiber-fiber interaction was proposed by modifying the rotary diffusion term of the Folgar-Tucker equation. This model was presented in a conference paper of the 29th International Conference of the Polymer Processing Society published by AIP conference proceeding. For modeling fiber interaction, the fiber dynamic simulation was introduced in order to obtain a global fiber interaction coefficient, which is sum function of the fiber concentration, aspect ratio, and angular velocity. The fiber orientation is predicted by using the proposed fiber interaction model incorporated into a computer aided engineering simulation package C-Mold. An experimental program has been carried out in which the fiber orientation distribution has been measured in 100 x 100 x 2 mm injection-molded plate and 100 x 80 x 2 mm injection-molded weld by analyzed with a high resolution 3D X-ray computed tomography system XVA-160α, and calculated by X-ray computed tomography imaging. The numerical prediction shows a good agreement with experimental validation. And the complex fiber orientation in the injection-molded weld was investigated.
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Rapid control of mold temperature during injection molding process
DOE Office of Scientific and Technical Information (OSTI.GOV)
Liparoti, Sara; Titomanlio, Giuseppe; Hunag, Tsang Min
2015-05-22
The control of mold surface temperature is an important factor that determines surface morphology and its dimension in thickness direction. It can also affect the frozen molecular orientation and the mold surface replicability in injection molded products. In this work, thin thermally active films were used to quickly control the mold surface temperature. In particular, an active high electrical conductivity carbon black loaded polyimide composites sandwiched between two insulating thin polymeric layers was used to condition the mold surface. By controlling the heating time, it was possible to control precisely the temporal variation of the mold temperature surface during themore » entire cycle. The surface heating rate was about 40°C/s and upon contact with the polymer the surface temperature decreased back to 40°C within about 5 s; the overall cycle time increased only slightly. The effect on cross section sample morphology of samples of iPP were analyzed and discussed on the basis of the recorded temperature evolution.« less
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Feasibility study of custom manufacturing methods of ionic polymer-metal composite sensors
NASA Astrophysics Data System (ADS)
Nelson, Shelby E.
The ability to create an ion exchange membrane with any shape or thickness through custom manufacturing techniques is highly desirable in ionic polymer-metal composite (IPMC) research. This is caused by the poor selection and limited availability of certain thicknesses of commercial ion exchange membranes. The objective of this study is to determine the feasibility of manufacturing custom ion exchange membranes for IPMC sensors. The manufacturing methods used in this study are extrusion, injection molding, and hot pressing. A commercial membrane from Golden Energy Fuel Cells (GEFC) is used as a comparison. After the membranes are fabricated, certain properties of the membranes are tested throughout each processing stage to determine if they are suitable to be developed into IPMCs. The three processing stages are pre-activation, activation (hydrated and dehydrated), and IPMC. It was observed that the stiffness of the membranes increased from pre-activation to activation and decreased from activation to IPMC. A more flexible membrane in an IPMC allows for larger cation displacement within the membrane. The extruded and injection molded membranes showed the most potential with having the lowest stiffness of all the samples; however, they were not able to be made into IPMCs due to repeated membrane failures in the primary plating process. Gas accumulated between the layers that formed in the membranes due to the extrusion and injection molding cooling process during manufacturing. The hot pressed membrane was the only custom manufactured membrane to be fully processed into an IPMC. The hot pressed and GEFC IPMC sensors were operated at 1 Hz, 5 Hz, and 10 Hz frequencies with the GEFC IPMC producing the strongest output voltage signal. While the extruded and injection molded membranes showed potential to become IPMCs with their high water uptake percentage, high ion exchange capacity, and low stiffness, more development is needed within the manufacturing process to make a uniform sample that does not fail during chemical processing.
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NASA Astrophysics Data System (ADS)
Hünnekens, Benedikt; Avramidis, Georg; Ohms, Gisela; Krause, Andreas; Viöl, Wolfgang; Militz, Holger
2018-05-01
The influence of plasma treatment performed at atmospheric pressure and ambient air as process gas by a dielectric barrier discharge (DBD) on the morphological and chemical surface characteristics of wood-polymer composites (WPC) was investigated by applying several surface-sensitive analytical methods. The surface free energy showed a distinct increase after plasma treatment for all tested materials. The analyzing methods for surface topography-laser scanning microscopy (LSM) and atomic force microscopy (AFM)-revealed a roughening induced by the treatment which is likely due to a degradation of the polymeric surface. This was accompanied by the formation of low-molecular-weight oxidized materials (LMWOMs), appearing as small globular structures. With increasing discharge time, the nodules increase in size and the material degradation proceeds. The surface degradation seems to be more serious for injection-molded samples, whereas the formation of nodules became more apparent and were evenly distributed on extruded surfaces. These phenomena could also be confirmed by scanning electron microscopy (SEM). In addition, differences between extruded and injection-molded surfaces could be observed. Besides the morphological changes, the chemical composition of the substrates' surfaces was affected by the plasma discharge. Infrared spectroscopy (ATR-FTIR) and X-ray photoelectron spectroscopy (XPS) indicated the formation of new oxygen containing polar groups on the modified surfaces.
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Fancello, Eduardo Alberto
2017-01-01
The purpose of this article is to present mechanical and physicochemical properties during in vitro degradation of PLGA material as craniofacial plates based on different values of injection molded temperatures. Injection molded plates were submitted to in vitro degradation in a thermostat bath at 37 ± 1°C by 16 weeks. The material was removed after 15, 30, 60, and 120 days; then bending stiffness, crystallinity, molecular weights, and viscoelasticity were studied. A significant decrease of molecular weight and mechanical properties over time and a difference in FT-IR after 60 days showed faster degradation of the material in the geometry studied. DSC analysis confirmed that the crystallization occurred, especially in higher melt temperature condition. DMA analysis suggests a greater contribution of the viscous component of higher temperature than lower temperature in thermomechanical behavior. The results suggest that physical-mechanical properties of PLGA plates among degradation differ per injection molding temperatures. PMID:29056968
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NASA Astrophysics Data System (ADS)
Bloß, P.; Böhme, A.; Müller, J.; Krajewsky, P.; Michaelis, J.
2014-05-01
A complete equipment for injection molding (IM) of a thermoplastic (TP) carrier and reaction injection molding (RIM) of polyurethane (PUR) coatings including IM and RIM machines, a color module for PUR, and a robot was built up. A modularly composed sliding split mold was constructed and manufactured allowing different parts including thicker (2 mm thickness) soft touch and thin (0.4 mm) lacquer PUR coatings. As TP PC/ABS and PA6 GF15 compounds were used, and aromatic and aliphatic PUR systems as well. From the parts made by IM+RIM, test specimens for peel force measurements were cut. These investigations were performed prior and after ageing under climatic conditions @ 50 % RH and temperature changes between -30 °C and 90 °C. By varying IM processing parameters, we have found that mold and TP temperatures are particularly important for the adhesion strength between TP and PUR. The waiting time between the end of TP cooling and PUR injection has a minor influence on its mean value. However, to short waiting times may result in inhomogeneous adhesion. It was surprising that surface defects of the TP carrier leads also to inhomogeneous adhesion. We have observed that ageing may cause an increase and decrease of adhesions strength depending on the TP+PUR system used. We have found that the results are valid only for the actual TP and PUR combination. A generalization seems to be inappropriate, hence, the actual combination should be investigated to prevent unwanted surprises when the coated TP part is in its application.
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Thermal and mechanical properties of 3D printed boron nitride - ABS composites
NASA Astrophysics Data System (ADS)
Quill, Tyler J.; Smith, Matthew K.; Zhou, Tony; Baioumy, Mohamed Gamal Shafik; Berenguer, Joao Paulo; Cola, Baratunde A.; Kalaitzidou, Kyriaki; Bougher, Thomas L.
2017-11-01
The current work investigates the thermal conductivity and mechanical properties of Boron Nitride (BN)-Acrylonitrile Butadiene Styrene (ABS) composites prepared using both 3D printing and injection molding. The thermally conductive, yet electrically insulating composite material provides a unique combination of properties that make it desirable for heat dissipation and packaging applications in electronics. Materials were fabricated via melt mixing on a twin-screw compounder, then injection molded or extruded into filament for fused deposition modeling (FDM) 3D printing. Compositions of up to 35 wt.% BN in ABS were prepared, and the infill orientation of the 3D printed composites was varied to investigate the effect on properties. Injection molding produced a maximum in-plane conductivity of 1.45 W/m-K at 35 wt.% BN, whereas 3D printed samples of 35 wt.% BN showed a value of 0.93 W/m-K, over 5 times the conductivity of pure ABS. The resulting thermal conductivity is anisotropic; with the through-plane thermal conductivity lower by a factor of 3 for injection molding and 4 for 3D printing. Adding BN flakes caused a modest increase in the flexural modulus, but resulted in a large decrease in the flexural strength and impact toughness. It is shown that although injection molding produces parts with superior thermal and mechanical properties, BN shows much potential as a filler material for rapid prototyping of thermally conductive composites.
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NASA Astrophysics Data System (ADS)
Zhou, Mingyong; Xiong, Xiang; Jiang, Bingyan; Weng, Can
2018-01-01
Polymer products with micro/nano-structures have excellent mechanical and optical properties, chemical resistance, and other advantages. Injection molding is one of the most potential techniques to fabricate polymer products with micro/nano-structures artificially in large numbers. In this study, a surface approach to fabricate high aspect ratio nanopillars and micro/nano combined structures was presented. Mold insert with micropillar arrays and nanopillars on its surface was prepared by combing anodic aluminum oxide (AAO) template and etched plate. Anti-sticking modification was done on the template to realize a better demolding quality. The influences of mold temperature and polymer material on the final replication quality were investigated. The results showed that the final replication quality of high aspect ratio nanopillars was greatly improved as compared with the unprocessed template. Polymer with low elongation at break was not suitable to fabricate structures with high aspect ratio via injection molding. For polypropylene surface, the experimental results of static contact angles were almost consistent with Cassie-Baxter equation. When the mold temperature reached 178 °C, hair-like polycarbonate nanopillars were observed, resulting in an excellent hydrophobic characteristic.
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NASA Astrophysics Data System (ADS)
Agne, Aboubakry; Barrière, Thierry
2018-05-01
Metal injection molding (MIM) is a process combining advantages of thermoplastic injection molding and powder metallurgy process in order to manufacture components with complex and near net-shape geometries. The debinding of a green component can be performed in two steps, first by using solvent debinding in order to extract the organic part of the binder and then by thermal degradation of the rest of the binder. A shorter and innovative method for extracting an organic binder involves the use of supercritical fluid instead of a regular solvent. The debinding via a supercritical fluid was recently investigated to extract organic binders contained in components obtained by Metal Injection Molding. It consists to put the component in an enclosure subjected to high pressure and temperature. The supercritical fluid has various properties depending on these two conditions, e.g., density and viscosity. The high-pressure combined with the high temperature during the process affect the component structure. Three mechanisms contributing to the deformation of the component can been differentiated: thermal expansion, binder extraction and supercritical fluid effect on the outer surfaces of the component. If one supposes that, the deformation due to binder extraction is negligible, thermal expansion and the fluid effect are probably the main mechanisms that can produce several stress. A finite-element model, which couples fluid-structures interaction and structural mechanics, has been developed and performed on the Comsol Multiphysics® finite-element software platform allowed to estimate the stress distribution during the supercritical debinding of MIM component composed of Inconel 718 powders, polypropylene, polyethylene glycol and stearic acid as binder. The proposed numerical simulations allow the estimation of the stress distribution with respect to the processing parameters for MIM components during the supercritical debinding process using a stationary solver.
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NASA Astrophysics Data System (ADS)
Kühr, C.; Spörrer, A.; Altstädt, V.
2014-05-01
The production of hard-soft-combinations via multi injection molding gained more and more importance in the last years. This is attributed to different factors. One principle reason is that the use of two-component injection molding technique has many advantages such as cancelling subsequent and complex steps and shortening the process chain. Furthermore this technique allows the combination of the properties of the single components like the high stiffness of the hard component and the elastic properties of the soft component. Because of the incompatibility of some polymers the adhesion on the interface has to be determined. Thereby adhesion is not only influenced by the applied polymers, but also by the injection molding parameters and the characteristics of the mold. Besides already known combinations of thermoplastics with thermoplastic elastomers (TPE), there consists the possibility to apply liquid silicone rubber (LSR) as soft component. A thermoplastic/LSR combination gains in importance due to the specific advantages of LSR to TPE. The faintly adhesion between LSR and thermoplastics is currently one of the key challenges when dealing with those combinations. So it is coercively necessary to improve adhesion between the two components by adding an adhesion promoter. To determine the promoters influence, it is necessary to develop a suitable testing method to investigate e.g. the peel resistance. The current German standard "VDI Richtlinie 2019', which is actually only employed for thermoplastic/TPE combinations, can serve as a model to determine the adhesion of thermoplastic/LSR combinations.
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Performance of disposable endoscopic forceps according to the manufacturing techniques.
Kwon, Chang-Il; Kim, Gwangil; Moon, Jong Pil; Yun, Ho; Ko, Weon Jin; Cho, Joo Young; Hong, Sung Pyo
2018-03-05
Recently, to lower the production costs and risk of infection, new disposable biopsy forceps made using simple manufacturing techniques have been introduced. However, the effects of the manufacturing techniques are unclear. The aim of this study was to evaluate which types of biopsy forceps could obtain good-quality specimens according to the manufacturing techniques. By using an in vitro nitrile glove popping model, we compared the popping ability among eight different disposable biopsy forceps (one pair of biopsy forceps with cups made by a cutting method [cutting forceps], four pairs of biopsy forceps with cups made by a pressing method [pressing forceps], and three pairs of biopsy forceps with cups made using a injection molding method [molding forceps]). Using an in vivo swine model, we compared the penetration depth and quality of specimen among the biopsy forceps. In the in vitro model, the molding forceps provided a significantly higher popping rate than the other forceps (cutting forceps, 25.0%; pressing forceps, 17.5%; and molding forceps, 41.7%; p = 0.006). In the in vivo model, the cutting and pressing forceps did not provide larger specimens, deeper biopsy specimen, and higher specimen adequacy than those obtained using the molding forceps (p = 0.2631, p = 0.5875, and p = 0.2147, respectively). However, the molding forceps showed significantly more common crush artifact than the others (cutting forceps, 0%; pressing forceps, 5.0%; and molding forceps, 43.3%; p = 0.0007). The molding forceps provided lower performance than the cutting and pressing forceps in terms of crush artifact.
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Injection Molding and its application to drug delivery.
Zema, Lucia; Loreti, Giulia; Melocchi, Alice; Maroni, Alessandra; Gazzaniga, Andrea
2012-05-10
Injection Molding (IM) consists in the injection, under high pressure conditions, of heat-induced softened materials into a mold cavity where they are shaped. The advantages the technique may offer in the development of drug products concern both production costs (no need for water or other solvents, continuous manufacturing, scalability, patentability) and technological/biopharmaceutical characteristics of the molded items (versatility of the design and composition, possibility of obtaining solid molecular dispersions/solutions of the active ingredient). In this article, process steps and formulation aspects relevant to IM are discussed, with emphasis on the issues and advantages connected with the transfer of this technique from the plastics industry to the production of conventional and controlled-release dosage forms. Moreover, its pharmaceutical applications thus far proposed in the primary literature, intended as either alternative manufacturing strategies for existing products or innovative systems with improved design and performance characteristics, are critically reviewed. Copyright © 2012 Elsevier B.V. All rights reserved.
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Park, Young-Seok; Chung, Shin-Hye; Shon, Won-Jun
2013-05-01
To evaluate osseointegration in rabbit tibiae and to investigate surface characteristics of novel zirconia implants made by powder injection molding (PIM) technique, using molds with and without roughened inner surfaces. A total of 20 rabbits received three types of external hex implants with identical geometry on the tibiae: machined titanium implants, PIM zirconia implants without mold etching, and PIM zirconia implants with mold etching. Surface characteristics of the three types of implant were evaluated. Removal torque tests and histomorphometric analyses were performed. The roughness of PIM zirconia implants was higher than that of machined titanium implants. The PIM zirconia implants exhibited significantly higher bone-implant contact and removal torque values than the machined titanium implants (P < 0.001). The PIM zirconia implants using roughened mold showed significantly higher removal torque values than PIM zirconia implants without using roughened mold (P < 0.001). It is concluded that the osseointegration of PIM zirconia implant is promising and PIM using roughened mold etching technique can produce substantially rough surfaces on zirconia implants. © 2012 John Wiley & Sons A/S.
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Analysis of the possibilities and limits of the Moldflow method
NASA Astrophysics Data System (ADS)
Brierre, M.
1982-01-01
The Moldflow information and computation service is presented. Moldflow is a computer program and data bank available as a computer aid to dimensioning thermoplastic injection molding equipment and processes. It is based on the simultaneous solution of thermal and rheological equations and is intended to completely simulate the injection process. The Moldflow system is described and algorithms are discussed, based on Moldflow listings.
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Gulsoy, H Ozkan; Pazarlioglu, Serdar; Gulsoy, Nagihan; Gundede, Busra; Mutlu, Ozal
2015-11-01
The research investigated the effect of Zr, Nb and Ti additions on mechanical, electrochemical properties and biocompatibility of injection molded 316L stainless steel. Addition of elemental powder is promoted to get high performance of sintered 316L stainless steels. The amount of additive powder plays a role in determining the sintered microstructure and all properties. In this study, 316L stainless steel powders used with the elemental Zr, Nb and Ti powders. A feedstock containing 62.5 wt% powders loading was molded at different injection molded temperature. The binders were completely removed from molded components by solvent and thermal debinding at different temperatures. The debinded samples were sintered at 1350°C for 60 min. Mechanical, electrochemical property and biocompatibility of the sintered samples were performed mechanical, electrochemical, SBF immersion tests and cell culture experiments. Results of study showed that sintered 316L and 316L with additives samples exhibited high corrosion properties and biocompatibility in a physiological environment. Copyright © 2015 Elsevier Ltd. All rights reserved.
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2010-01-01
School of Enviromental and Biological Sciences New Brunswick, NJ 08903 FTR 214 Defense Logistics Agency 8725 John J. Kingsman Rd Fort Belvoir, VA...Precision Automation X Injection Mold 1100 Rack Stock America X Injection Mold 1400 Rack AllPax X Enviromental Chamber Model: 11-679-25C Fisher
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USDA-ARS?s Scientific Manuscript database
Extruded/injection-molded composites were produced from plantain flour blended with ethylene vinyl-alcohol (EVA) and glycerol. Scanning electron microscopy showed composites had a smooth surface and excellent compatibility between plantain flour, EVA and glycerol. The impact of increased plantain fl...
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NASA Astrophysics Data System (ADS)
Koizumi, Koji; Charles, Ted; de Keyser, Hendrik
Phenolic Molding Compounds continue to exhibit well balanced properties such as heat resistance, chemical resistance, dimensional stability, and creep resistance. They are widely applied in electrical, appliance, small engine, commutator, and automotive applications. As the focus of the automotive industry is weight reduction for greater fuel efficiency, phenolic molding compounds become appealing alternatives to metals. Current market volumes and trends, formulation components and its impact on properties, and a review of common manufacturing methods are presented. Molding processes as well as unique advanced techniques such as high temperature molding, live sprue, and injection/compression technique provide additional benefits in improving the performance characterisitics of phenolic molding compounds. Of special interest are descriptions of some of the latest innovations in automotive components, such as the phenolic intake manifold and valve block for dual clutch transmissions. The chapter also characterizes the most recent developments in new materials, including long glass phenolic molding compounds and carbon fiber reinforced phenolic molding compounds exhibiting a 10-20-fold increase in Charpy impact strength when compared to short fiber filled materials. The role of fatigue testing and fatigue fracture behavior presents some insight into long-term reliability and durability of glass-filled phenolic molding compounds. A section on new technology outlines the important factors to consider in modeling phenolic parts by finite element analysis and flow simulation.
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NASA Astrophysics Data System (ADS)
Khavekar, Rajendra; Vasudevan, Hari, Dr.; Modi, Bhavik
2017-08-01
Two well-known Design of Experiments (DoE) methodologies, such as Taguchi Methods (TM) and Shainin Systems (SS) are compared and analyzed in this study through their implementation in a plastic injection molding unit. Experiments were performed at a perfume bottle cap manufacturing company (made by acrylic material) using TM and SS to find out the root cause of defects and to optimize the process parameters for minimum rejection. Experiments obtained the rejection rate to be 8.57% from 40% (appx.) during trial runs, which is quiet low, representing successful implementation of these DoE methods. The comparison showed that both methodologies gave same set of variables as critical for defect reduction, but with change in their significance order. Also, Taguchi methods require more number of experiments and consume more time compared to the Shainin System. Shainin system is less complicated and is easy to implement, whereas Taguchi methods is statistically more reliable for optimization of process parameters. Finally, experimentations implied that DoE methods are strong and reliable in implementation, as organizations attempt to improve the quality through optimization.
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Development of bio-sourced binder to metal injection moulding
NASA Astrophysics Data System (ADS)
Royer, Alexandre; Barrière, Thierry; Gelin, Jean-Claude
2016-10-01
In the MIM process the binder play the most important role. It provides fluidity of the feedstock mixture for injection molding and adhesion of the powder to keep the molded shape. The binder must provide strength and cohesion for the molded part, must be easy to be removed from the molded part, and must be the recyclable, environmentally friendly and economical ones. The goal of this study is to develop a binder environmentally friendly. For this, a study of formulation based on polyethylene glycol, because of is water debinding properties, was made. Polylactic acid and Polyhydroxyalkanoates were investigated as bio sourced polymers. The chemical, miscibility and rheological behavior of the binder formulation were investigated.
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Apparatus for injection casting metallic nuclear energy fuel rods
Seidel, Bobby R.; Tracy, Donald B.; Griffiths, Vernon
1991-01-01
Molds for making metallic nuclear fuel rods are provided which present reduced risks to the environment by reducing radioactive waste. In one embodiment, the mold is consumable with the fuel rod, and in another embodiment, part of the mold can be re-used. Several molds can be arranged together in a cascaded manner, if desired, or several long cavities can be integrated in a monolithic multiple cavity re-usable mold.
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DOE Office of Scientific and Technical Information (OSTI.GOV)
Nguyen, Ba Nghiep; Sanborn, Scott E.; Mathur, Raj N.
2014-08-15
This report describes the technical progresses made during the third quarter of FY 2014: 1) Autodesk introduced the options for fiber inlet condition to the 3D solver. These options are already available in the mid-plane/dual domain solver. 2) Autodesk improved the accuracy of 3D fiber orientation calculation around the gate. 3) Autodesk received consultant services from Prof. C.L. Tucker at the University of Illinois on the implementation of the reduced order model for fiber length, and discussed with Prof. Tucker the methods to reduce memory usage. 4) PlastiComp delivered to PNNL center-gated and edge-fan-gated 20-wt% to 30-wt% LCF/PP and LCF/PA66more » (7”x7”x1/8”) plaques molded by the in-line direct injection molding (D-LFT) process. 5) PlastiComp molded ASTM tensile, flexural and impact bars under the same D-LFT processing conditions used for plaques for Certification of Assessment and ascertaining the resultant mechanical properties. 6) Purdue developed a new polishing routine, utilizing the automated polishing machine, to reduce fiber damage during surface preparation. 7) Purdue used a marker-based watershed segmentation routine, in conjunction with a hysteresis thresholding technique, for fiber segmentation during fiber orientation measurement. 8) Purdue validated Purdue’s fiber orientation measurement method using the previous fiber orientation data obtained from the Leeds machine and manually measured data by the University of Illinois. 9) PNNL conducted ASMI mid-plane analyses for a 30wt% LCF/PP plaque and compared the predicted fiber orientations with the measured data provided by Purdue University at the selected locations on this plaque. 10) PNNL put together the DOE 2014 Annual Merit Review (AMR) presentation with the team and presented it at the AMR meetings on June 17, 2014. 11) PNNL built ASMI dual domain models for the Toyota complex part and commenced mold filling analyses of the complex part with different wall thicknesses in order to support part molding. 12) Toyota and Magna discussed with PNNL on tool modification for molding the complex part. Toyota sent the CAD files of the complex part to PNNL to build ASMI models of the part for mold filling analysis to provide guidance to tooling and part molding.« less
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NASA Technical Reports Server (NTRS)
Silverman, B.
1979-01-01
All available newly developed nonmetallic thermally stable polymers were examined for the development of processes and techniques by compression molding, injection molding, or thermoforming cabin interior parts. Efforts were directed toward developing molding techniques of new polymers to economically produce usable nonmetallic molded parts. Data on the flame resistant characteristics of the materials were generated from pilot plant batches. Preliminary information on the molding characteristics of the various thermoplastic materials was obtained by producing actual parts.
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Automatic design of conformal cooling channels in injection molding tooling
NASA Astrophysics Data System (ADS)
Zhang, Yingming; Hou, Binkui; Wang, Qian; Li, Yang; Huang, Zhigao
2018-02-01
The generation of cooling system plays an important role in injection molding design. A conformal cooling system can effectively improve molding efficiency and product quality. This paper provides a generic approach for building conformal cooling channels. The centrelines of these channels are generated in two steps. First, we extract conformal loops based on geometric information of product. Second, centrelines in spiral shape are built by blending these loops. We devise algorithms to implement the entire design process. A case study verifies the feasibility of this approach.
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Plasmonic gold nanostars as optical nano-additives for injection molded polymer composites
NASA Astrophysics Data System (ADS)
Boyne, Devon A.; Orlicki, Joshua A.; Walck, Scott D.; Savage, Alice M.; Li, Thomas; Griep, Mark H.
2017-10-01
Nanoscale engineering of noble metal particles has provided numerous material configurations to selectively confine and manipulate light across the electromagnetic spectrum. Transitioning these materials to a composite form while maintaining the desired resonance properties has proven challenging. In this work, the successful integration of plasmon-focusing gold nanostars (GNSs) into polymer nanocomposites (PNCs) is demonstrated. Tailored GNSs are produced with over a 90% yield and methods to control the branching structures are shown. A protective silica capping shell is employed on the nanomaterials to facilitate survivability in the high temperate/high shear processing parameters to create optically-tuned injection molded PNCs. The developed GNS PNCs possess dichroic scattering and absorption behavior, opening up potential applications in the fields of holographic imaging, optical filtering and photovoltaics.
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Injection molding plants are large consumers of electricity. At its current level of operations, Harbec Plastics (Ontario, NY) uses about 2,000,000 kilowatt-hours of electricity per year. Based on the US average fuel mix, approximately 1.5 pounds of CO2
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Research study demonstrates computer simulation can predict warpage and assist in its elimination
NASA Astrophysics Data System (ADS)
Glozer, G.; Post, S.; Ishii, K.
1994-10-01
Programs for predicting warpage in injection molded parts are relatively new. Commercial software for simulating the flow and cooling stages of injection molding have steadily gained acceptance; however, warpage software is not yet as readily accepted. This study focused on gaining an understanding of the predictive capabilities of the warpage software. The following aspects of this study were unique. (1) Quantitative results were found using a statistically designed set of experiments. (2) Comparisons between experimental and simulation results were made with parts produced in a well-instrumented and controlled injection molding machine. (3) The experimental parts were accurately measured on a coordinate measuring machine with a non-contact laser probe. (4) The effect of part geometry on warpage was investigated.
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Structural Reorganization of CNC in Injection-Molded CNC/PBAT Materials under Thermal Annealing.
Mariano, Marcos; El Kissi, Nadia; Dufresne, Alain
2016-10-04
Composite materials were prepared by extrusion and injection molding from polybutyrate adipate terephthalate (PBAT) and high aspect ratio cellulose nanocrystals (CNCs) extracted from capim dourado fibers. Three CNC contents were used, corresponding to 0.5, 1, and 2 times the theoretical percolation threshold. Small-amplitude oscillary shear (SAOS) experiments show that as the CNC content increases, a more elastic behavior is observed but no percolating network can form within the polymeric matrix as a result of the high shear rates involved during the injection-molding process. Annealing of the samples at 170 °C was performed, and the possible reorganization of the nanofiller was investigated. This reorganization was further elucidated using 2D-SAOS and creep experiments.
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Investigation of compression behavior of PE/EVA foam injection molded parts
NASA Astrophysics Data System (ADS)
Spina, Roberto
2017-10-01
The main objective of the presented work is to evaluate the compression behavior of a polymeric foam blend by using a robust framework for the testing sequence of foaming injection molded parts, with the aim of establishing a standard testing cycle for the evaluation of new matrix material. The research purpose is to assess parameters influencing compression behavior and give useful suggestions for the implementation of a finite element analysis. The polymeric blend consisted of a mixture of low density polyethylenes (LDPEs), a high-density polyethylene (HDPE), an ethylene-vinyl acetate (EVA) and an azodicarbonamide (ADC). The thermal, rheological and compression properties of the blend are fully described, as well as the injection molding process for two specimen types.
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Numerical-experimental investigation of PE/EVA foam injection molded parts
NASA Astrophysics Data System (ADS)
Spina, Roberto
The main objective of the presented work is to propose a robust framework to test foaming injection molded parts, with the aim of establishing a standard testing cycle for the evaluation of a new foam material based on numerical and experimental results. The research purpose is to assess parameters influencing several aspects, such as foam morphology and compression behavior, using useful suggestions from finite element analysis. The investigated polymeric blend consisted of a mixture of low density polyethylenes (LDPEs), a high-density polyethylene (HDPE), an ethylene-vinyl acetate (EVA) and an azodicarbonamide (ADC). The thermal, rheological and compression properties of the blend are fully described, as well as the numerical models and the parameters of the injection molding process.
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Controle de la morphologie d'hydrogels poreux a partir de structures polymeres
NASA Astrophysics Data System (ADS)
Esquirol, Anne-Laure
This master thesis presents a new fabrication method to prepare hydrogels with fully interconnected and tunable macropore networks prepared with co-continuous polymer blends. The main contributions are: (1) a hydrogel fabrication process providing a high control over the average pore size diameter, their volume fraction and their interconnectivity; (2) the microstructural characterization of porous hydrogels with new techniques such as X-ray microtomography and (3) the preparation of porous gels with industrial equipment such as extruders and injection molding presses. The development and improvement of methods and techniques to prepare porous polymers and porous gels have been intensive areas of research in materials science over the past 20 years because of their potential use in fields as diverse as high performance membranes and filtration devices, supports for catalysis and biochemical reactions, encapsulating devices for drug release, and scaffolds for cells seeding and proliferation. For this last application, in tissue engineering, some typical parameters related to porosity must be rigorously controlled: (1) the average pore size diameter; (2) the pore volume fraction; (3) the pore interconnectivity. Porous hydrogels are excellent candidates due to their similarities with the extracellular matrix (composition, mechanical properties and diffusion properties). A certain number of methods and techniques have been developed and studied to prepare gels comprising microstructured 3-D networks of (more or less) interconnected pores (also called sometimes microfluidic gels or (macro)porous gels). Poly(L-lactide) (PLA) porous materials were realized from immiscible and co-continuous binary blends of polystyrene/poly(L-lactide) (PS/PLA) at 50/50 %vol prepared by different methods : (1) internal mixer (cubic samples with 0.8 mm sides) and (2) extrusion followed by injection molding which allows the fabrication of bars with superior dimensions (0.95 cm x 1.25 cm x 6.3 cm). Quiescent annealing of the binary blends was performed at 190 °C to tune the characteristic dimensions of the co-continuous morphology: (1) 0, 10, 30, 60 and 90 min for cubic samples and (2) 0, 10, 20 and 30 min for bars. Afterwards, the PLA phase has been isolated by a specific solvent extraction of the PS phase to obtain porous PLA molds. Gravimetric analysis have demonstrated a co-continuity superior to 95% for cubic samples and superior to 85% for the bars. This morphology was analyzed by scanning electron microscopy (SEM) for each annealing time (for the cubic samples). Image analysis performed on the SEM micrographs have demonstrated that the average pore diameter can range from 3 mum to over 400 mum and that the specific interfacial area ranges from 5800 cm-1 to 45 cm-1, for annealing times going from 0 min to 90 min). The porosity of the bars was observed by X-ray microtomography and shows that the average pore diameter ranges from 10 mum to 500 mum (annealing from 10 min to 30 min). Solutions of agar or alginate were subsequently injected into the PLA porous molds by using a manual injection system, followed by an in situ gelification. Visual inspections and optical microscope observations show a complete injection for molds with average pore sizes over 20 mum (cubic samples) and over 300 mum (for bars). These assumptions are also supported by the gels morphology characterization. The second polymer phase (PLA) was subsequently dissolved using a second selective solvent, leaving only the porous gel structures. X-ray microtomography analysis, which provide 2-D and 3-D images, have demonstrated that the morphologies of the porous gels are similar to the PLA molds microstructures. For example, porous gels prepared with cubic PLA molds annealed during 60 min, show an average pore size of about 285 mum (as compared to 200 mum for the PLA molds) and a specific interfacial area of 70 cm -1 (as compared to 100 cm-1 for the PLA molds). Similar results were obtained for the porous gels prepared with the porous PLA bars (qualitative observation). The effectiveness of two sterilization methods has been proven on nutrient agar (NA) and "Brain Heart Infusion" (BHI) with no bacterial colonies apparition. The first method is the freeze-drying followed by an oven treatment at 120 °C in a sterile environment. The porous gel morphology was characterized by X-ray microtomography before and after freeze-drying, and after rehydration, demonstrating the conservation of the macroscopic dimensions of the gels, of their morphologies and porosities. The second method is the successive baths in an ethanol solution. Finally mechanical compression tests have shown that porous gels, as can be expected, have a lower compressive resistance as compared to non-porous hydrogels. (Abstract shortened by UMI.).
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Electron-Beam Vapor Deposition of Mold Inserts Final Report CRADA No. TSB-777-94
DOE Office of Scientific and Technical Information (OSTI.GOV)
Shepp, T.; Feeley, T.
Lawrence Livermore National Laboratory and H.G.G. Laser Fare, Inc. studied the application of electron-beam vapor deposition technology to the production of mold inserts for use in an injection molding machine by Laser Fare. Laser Fare provided LLNL with the requirements of the mold inserts as well as sample inserts. LLNL replicated the mold insert(s) to Laser Fare for testing by Laser Fare.
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Qanungo, Anchal; Aras, Meena Ajay; Chitre, Vidya; Coutinho, Ivy; Rajagopal, Praveen; Mysore, Ashwin
2016-01-01
Purpose: The aim of this in vivo study was to compare the single-step border molding technique using injectable heavy viscosity addition silicone with sectional border molding technique using low fusing impression compound by evaluating the retention of heat cure trial denture bases. Materials and Methods: Ten completely edentulous patients in need of prostheses were included in this study. Two border molding techniques, single-step (Group 1) and sectional (Group 2), were compared for retention. Both border molding techniques were performed in each patient. In both techniques, definitive wash impression was made with light viscosity addition silicone. The final results were analyzed using paired t-test to determine whether significant differences existed between the groups. Results: The t-value (3.031) infers that there was a significant difference between Group 1 and Group 2 (P = 0.014). The retention obtained in Group 2 (mean = 9.05 kgf) was significantly higher than that of Group 1 (mean = 8.26 kgf). Conclusion: Sectional border molding technique proved to be more retentive as compared to single-step border molding although clinically the retention appeared comparable. PMID:27746597
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Electroforming of optical tooling in high-strength Ni-Co alloy
NASA Astrophysics Data System (ADS)
Stein, Berl
2003-05-01
Plastic optics are often mass produced by injection, compression or injection-compression molding. Optical quality molds can be directly machined in appropriate materials (tool steels, electroless nickel, aluminum, etc.), but much greater cost efficiency can be achieved with electroformed modl inserts. Traditionally, electroforming of optical quality mold inserts has been carried out in nickel, a material much softer than tool steels which, when hardened to 45 - 50 HRc usually exhibit high wear resistance and long service life (hundreds of thousands of impressions per mold). Because of their low hardness (< 20 HRc), nickel molds can produce only tens of thousands of parts before they are scrapped due to wear or accidental damage. This drawback prevented their wider usage in general plastic and optical mold making. Recently, NiCoForm has developed a proprietary Ni-CO electroforming bath combining the high strength and wear resistance of the alloy with the low stress and high replication fidelity typical of pure nickel electroforming. This paper will outline the approach to electroforming of optical quality tooling in low stress, high strength Ni-Co alloy and present several examples of electroformed NiColoy mold inserts.
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Numerical study on injection parameters optimization of thin wall and biodegradable polymers parts
NASA Astrophysics Data System (ADS)
Santos, C.; Mendes, A.; Carreira, P.; Mateus, A.; Malça, C.
2017-07-01
Nowadays, the molds industry searches new markets, with diversified and added value products. The concept associated to the production of thin walled and biodegradable parts mostly manufactured by injection process has assumed a relevant importance due to environmental and economic factors. The growth of a global consciousness about the harmful effects of the conventional polymers in our life quality associated with the legislation imposed, become key factors for the choice of a particular product by the consumer. The target of this work is to provide an integrated solution for the injection of parts with thin walls and manufactured using biodegradable materials. This integrated solution includes the design and manufacture processes of the mold as well as to find the optimum values for the injection parameters in order to become the process effective and competitive. For this, the Moldflow software was used. It was demonstrated that this computational tool provides an effective responsiveness and it can constitute an important tool in supporting the injection molding of thin-walled and biodegradable parts.
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NASA Astrophysics Data System (ADS)
Öktem, H.
2012-01-01
Plastic injection molding plays a key role in the production of high-quality plastic parts. Shrinkage is one of the most significant problems of a plastic part in terms of quality in the plastic injection molding. This article focuses on the study of the modeling and analysis of the effects of process parameters on the shrinkage by evaluating the quality of the plastic part of a DVD-ROM cover made with Acrylonitrile Butadiene Styrene (ABS) polymer material. An effective regression model was developed to determine the mathematical relationship between the process parameters (mold temperature, melt temperature, injection pressure, injection time, and cooling time) and the volumetric shrinkage by utilizing the analysis data. Finite element (FE) analyses designed by Taguchi (L27) orthogonal arrays were run in the Moldflow simulation program. Analysis of variance (ANOVA) was then performed to check the adequacy of the regression model and to determine the effect of the process parameters on the shrinkage. Experiments were conducted to control the accuracy of the regression model with the FE analyses obtained from Moldflow. The results show that the regression model agrees very well with the FE analyses and the experiments. From this, it can be concluded that this study succeeded in modeling the shrinkage problem in our application.
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Vu, Lien T; Chen, Chao-Chang A; Lee, Chia-Cheng; Yu, Chia-Wei
2018-04-20
This study aims to develop a compensating method to minimize the shrinkage error of the shell mold (SM) in the injection molding (IM) process to obtain uniform optical power in the central optical zone of soft axial symmetric multifocal contact lenses (CL). The Z-shrinkage error along the Z axis or axial axis of the anterior SM corresponding to the anterior surface of a dry contact lens in the IM process can be minimized by optimizing IM process parameters and then by compensating for additional (Add) powers in the central zone of the original lens design. First, the shrinkage error is minimized by optimizing three levels of four IM parameters, including mold temperature, injection velocity, packing pressure, and cooling time in 18 IM simulations based on an orthogonal array L 18 (2 1 ×3 4 ). Then, based on the Z-shrinkage error from IM simulation, three new contact lens designs are obtained by increasing the Add power in the central zone of the original multifocal CL design to compensate for the optical power errors. Results obtained from IM process simulations and the optical simulations show that the new CL design with 0.1 D increasing in Add power has the closest shrinkage profile to the original anterior SM profile with percentage of reduction in absolute Z-shrinkage error of 55% and more uniform power in the central zone than in the other two cases. Moreover, actual experiments of IM of SM for casting soft multifocal CLs have been performed. The final product of wet CLs has been completed for the original design and the new design. Results of the optical performance have verified the improvement of the compensated design of CLs. The feasibility of this compensating method has been proven based on the measurement results of the produced soft multifocal CLs of the new design. Results of this study can be further applied to predict or compensate for the total optical power errors of the soft multifocal CLs.
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Influence of melt mixer on injection molding of thermoset elastomers
NASA Astrophysics Data System (ADS)
Rochman, Arif; Zahra, Keith
2016-10-01
One of the drawbacks in injection molding is that the plasticizing screw is short such that polymers having high concentrations of additives, such as thermoset elastomers, might not mix homogeneously within the short period of time during the plasticizing stage. In this study, various melt mixers inside the nozzle chamber, together forming a mixing nozzle, were developed. Three different materials were investigated, namely nitrile butadiene rubber (NBR), ethylene propylene-diene monomer (EPDM) and fluorocarbon (FKM). The use of these melt mixers resulted in better homogeneity and properties of the molded parts despite a curing time reduction of 10 s. This was due to the increase in mixing and shearing introduced a higher rate of crosslinking formation in the molded parts.
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Effects of mold design of aspheric projector lens for head up display
NASA Astrophysics Data System (ADS)
Chen, Chao-Chang A.; Tang, Jyun-Cing; Teng, Lin-Ming
2010-08-01
This paper investigates the mold design and related effects on an aspheric projector lens for Head Up Display (HUD) with injection molding process. Injection flow analysis with a commercial software, Moldex3D has been used to simulate this projector lens for filling, packing, shrinkage, and flow-induced residual stress. This projector lens contains of variant thickness due to different aspheric design on both surfaces. Defects may be induced as the melt front from the gate into the cavity with jet-flow phenomenon, short shot, weld line, and even shrinkage. Thus, this paper performs a gate design to find the significant parameters including injection velocity, melt temperature, and mold temperature. After simulation by the Moldex3D, gate design for the final assembly of Head Up Display (HUD) has been obtained and then experimental tests have been proceeded for verification of short-shot, weight variation, and flow-induced stress. Moreover, warpage analysis of the Head Up Display (HUD) can be integrated with the optical design specification in future work.
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Fancello, Eduardo Alberto
2017-01-01
Two groups of PLGA specimens with different geometries (notched and unnotched) were injection molded under two melting temperatures and flow rates. The mechanical properties, morphology at the fracture surface, and residual stresses were evaluated for both processing conditions. The morphology of the fractured surfaces for both specimens showed brittle and smooth fracture features for the majority of the specimens. Fracture images of the notched specimens suggest that the surface failure mechanisms are different from the core failure. Polarized light techniques indicated birefringence in all specimens, especially those molded with lower temperature, which suggests residual stress due to rapid solidification. DSC analysis confirmed the existence of residual stress in all PLGA specimens. The specimens molded using the lower injection temperature and the low flow rate presented lower loss tangent values according to the DMA and higher residual stress as shown by DSC, and the photoelastic analysis showed extensive birefringence. PMID:28848605
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Ballyns, Jeffery J; Gleghorn, Jason P; Niebrzydowski, Vicki; Rawlinson, Jeremy J; Potter, Hollis G; Maher, Suzanne A; Wright, Timothy M; Bonassar, Lawrence J
2008-07-01
This study demonstrates for the first time the development of engineered tissues based on anatomic geometries derived from widely used medical imaging modalities such as computed tomography (CT) and magnetic resonance imaging (MRI). Computer-aided design and tissue injection molding techniques have demonstrated the ability to generate living implants of complex geometry. Due to its complex geometry, the meniscus of the knee was used as an example of this technique's capabilities. MRI and microcomputed tomography (microCT) were used to design custom-printed molds that enabled the generation of anatomically shaped constructs that retained shape throughout 8 weeks of culture. Engineered constructs showed progressive tissue formation indicated by increases in extracellular matrix content and mechanical properties. The paradigm of interfacing tissue injection molding technology can be applied to other medical imaging techniques that render 3D models of anatomy, demonstrating the potential to apply the current technique to engineering of many tissues and organs.
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NASA Astrophysics Data System (ADS)
Pignon, Baptiste; Sobotka, Vincent; Boyard, Nicolas; Delaunay, Didier
2017-10-01
Two different analytical models were presented to determine cycle parameters of thermoplastics injection process. The aim of these models was to provide quickly a first set of data for mold temperature and cooling time. The first model is specific to amorphous polymers and the second one is dedicated to semi-crystalline polymers taking the crystallization into account. In both cases, the nature of the contact between the polymer and the mold could be considered as perfect or not (thermal contact resistance was considered). Results from models are compared with experimental data obtained with an instrumented mold for an acrylonitrile butadiene styrene (ABS) and a polypropylene (PP). Good agreements were obtained for mold temperature variation and for heat flux. In the case of the PP, the analytical crystallization times were compared with those given by a coupled model between heat transfer and crystallization kinetics.
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Ultrasound - Aided ejection in micro injection molding
NASA Astrophysics Data System (ADS)
Masato, D.; Sorgato, M.; Lucchetta, G.
2018-05-01
In this work, an ultrasound-aided ejection system was designed and tested for different polymers (PS, COC and POM) and mold topographies. The proposed solution aims at reducing the ejection friction by decreasing the adhesion component of the frictional force, which is controlled by the contact area developed during the filling stage of the injection molding process. The experimental results indicate a positive effect of ultrasound vibration on the friction force values, with a maximum reduction of 16. Moreover, it is demonstrated that the ultrasound effect is strictly related to both polymer selection and mold roughness. The combined effect on the ejection force of mold surface roughness, melt viscosity during filling and polymer elastic modulus at ejection was modeled to the experimental data, in order to demonstrate that the effect of ultrasound vibration on the ejection friction reduction is due to the heating of the contact interface and the consequent reduction of the polymer elastic modulus.
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Lee, Dae-Sik; Yang, Haesik; Chung, Kwang-Hyo; Pyo, Hyeon-Bong
2005-08-15
Because of their broad applications in biomedical analysis, integrated, polymer-based microdevices incorporating micropatterned metallic and insulating layers are significant in contemporary research. In this study, micropatterns for temperature sensing and microelectrode sets for electroanalysis have been implemented on an injection-molded thin polymer membrane by employing conventional semiconductor processing techniques (i.e., standard photolithographic methods). Cyclic olefin copolymer (COC) is chosen as the polymer substrate because of its high chemical and thermal stability. A COC 5-in. wafer (1-mm thickness) is manufactured using an injection molding method, in which polymer membranes (approximately 130 microm thick and 3 mm x 6 mm in area) are implemented simultaneously in order to reduce local thermal mass around micropatterned heaters and temperature sensors. The highly polished surface (approximately 4 nm within 40 microm x 40 microm area) of the fabricated COC wafer as well as its good resistance to typical process chemicals makes it possible to use the standard photolithographic and etching protocols on the COC wafer. Gold micropatterns with a minimum 5-microm line width are fabricated for making microheaters, temperature sensors, and microelectrodes. An insulating layer of aluminum oxide (Al2O3) is prepared at a COC-endurable low temperature (approximately 120 degrees C) by using atomic layer deposition and micropatterning for the electrode contacts. The fabricated microdevice for heating and temperature sensing shows improved performance of thermal isolation, and microelectrodes display good electrochemical performances for electrochemical sensors. Thus, this novel 5-in. wafer-level microfabrication method is a simple and cost-effective protocol to prepare polymer substrate and demonstrates good potential for application to highly integrated and miniaturized biomedical devices.
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Eggenreich, K; Windhab, S; Schrank, S; Treffer, D; Juster, H; Steinbichler, G; Laske, S; Koscher, G; Roblegg, E; Khinast, J G
2016-05-30
The objective of the present study was to develop a one-step process for the production of tablets directly from primary powder by means of injection molding (IM), to create solid-dispersion based tablets. Fenofibrate was used as the model API, a polyvinyl caprolactame-polyvinyl acetate-polyethylene glycol graft co-polymer served as a matrix system. Formulations were injection-molded into tablets using state-of-the-art IM equipment. The resulting tablets were physico-chemically characterized and the drug release kinetics and mechanism were determined. Comparison tablets were produced, either directly from powder or from pre-processed pellets prepared via hot melt extrusion (HME). The content of the model drug in the formulations was 10% (w/w), 20% (w/w) and 30% (w/w), respectively. After 120min, both powder-based and pellet-based injection-molded tablets exhibited a drug release of 60% independent of the processing route. Content uniformity analysis demonstrated that the model drug was homogeneously distributed. Moreover, analysis of single dose uniformity also revealed geometric drug homogeneity between tablets of one shot. Copyright © 2016 Elsevier B.V. All rights reserved.
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Polylactide-based renewable green composites from agricultural residues and their hybrids.
Nyambo, Calistor; Mohanty, Amar K; Misra, Manjusri
2010-06-14
Agricultural natural fibers like jute, kenaf, sisal, flax, and industrial hemp have been extensively studied in green composites. The continuous supply of biofibers in high volumes to automotive part makers has raised concerns. Because extrusion followed by injection molding drastically reduces the aspect ratio of biofibers, the mechanical performance of injection molded agricultural residue and agricultural fiber-based composites are comparable. Here, the use of inexpensive agricultural residues and their hybrids that are 8-10 times cheaper than agricultural fibers is demonstrated to be a better way of getting sustainable materials with better performance. Green renewable composites from polylactide (PLA), agricultural residues (wheat straw, corn stover, soy stalks, and their hybrids) were successfully prepared through twin-screw extrusion, followed by injection molding. The effect on mechanical properties of varying the wheat straw amount from 10 to 40 wt % in PLA-wheat straw composites was studied. Tensile moduli were compared with theoretical calculations from the rule of mixture (ROM). Combination of agricultural residues as hybrids is proved to reduce the supply chain concerns for injection molded green composites. Densities of the green composites were found to be lower than those of conventional glass fiber composites.
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Effect of fast mold surface temperature evolution on iPP part morphology gradients
NASA Astrophysics Data System (ADS)
Liparoti, Sara; Sorrentino, Andrea; Guzman, Gustavo; Cakmak, Mukerrem; Titomanlio, Giuseppe
2016-03-01
The control of mold surface temperature is an important factor that affects the sample surface morphology as well as the structural gradients (orientation crystal size, and type) as well as cooling stresses. The frozen layer thickness formed during the filling stage also has a very significant effect on the flow resistance and thus on the resulting pressure drop and flow length in thin wall parts. The possibility to have a hot mold during filling and a quick cooling soon afterward is a significant process enhancement particularly for specialized applications such as micro injection molding and for the reproduction of micro structured surfaces. Up to now, several methods (electromagnetic, infrared, hot vapor fleshing etc,) were tried to achieve fast temperature evolution of the mold. Unfortunately, all these methods require a complex balance between thermal and mechanical problems, equipment cost, energy consumption, safety, molding cycle time and part quality achievable. In this work, a thin electrical resistance was designed and used to generate a fast and confined temperature variation on mold surface (by joule effect). Since the whole temperature evolution can take place in a few seconds, one can couple the advantages of a high surface temperature during filling with the advantages of a low mold temperature, fast cooling and low heating dissipation. Some experiments were performed with a commercial iPP resin. The effects of the surface temperature and of the heating time (under constant electric power) on surface finishing and on the final morphology (thickness and structure of the different layers) are explored and discussed.
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Effect of fast mold surface temperature evolution on iPP part morphology gradients
DOE Office of Scientific and Technical Information (OSTI.GOV)
Liparoti, Sara; Sorrentino, Andrea; Guzman, Gustavo
The control of mold surface temperature is an important factor that affects the sample surface morphology as well as the structural gradients (orientation crystal size, and type) as well as cooling stresses. The frozen layer thickness formed during the filling stage also has a very significant effect on the flow resistance and thus on the resulting pressure drop and flow length in thin wall parts. The possibility to have a hot mold during filling and a quick cooling soon afterward is a significant process enhancement particularly for specialized applications such as micro injection molding and for the reproduction of micromore » structured surfaces. Up to now, several methods (electromagnetic, infrared, hot vapor fleshing etc,) were tried to achieve fast temperature evolution of the mold. Unfortunately, all these methods require a complex balance between thermal and mechanical problems, equipment cost, energy consumption, safety, molding cycle time and part quality achievable. In this work, a thin electrical resistance was designed and used to generate a fast and confined temperature variation on mold surface (by joule effect). Since the whole temperature evolution can take place in a few seconds, one can couple the advantages of a high surface temperature during filling with the advantages of a low mold temperature, fast cooling and low heating dissipation. Some experiments were performed with a commercial iPP resin. The effects of the surface temperature and of the heating time (under constant electric power) on surface finishing and on the final morphology (thickness and structure of the different layers) are explored and discussed.« less
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Rodríguez-Yáñez, Alicia Berenice; Méndez-Vázquez, Yaileen
2014-01-01
Process windows in injection molding are habitually built with only one performance measure in mind. In reality, a more realistic picture can be obtained when considering multiple performance measures at a time, especially in the presence of conflict. In this work, the construction of process windows for injection molding (IM) is undertaken considering two and three performance measures in conflict simultaneously. The best compromises between the criteria involved are identified through the direct application of the concept of Pareto-dominance in multiple criteria optimization. The aim is to provide a formal and realistic strategy to set processing conditions in IM operations. The resulting optimization approach is easily implementable in MS Excel. The solutions are presented graphically to facilitate their use in manufacturing plants. PMID:25530927
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Rodríguez-Yáñez, Alicia Berenice; Méndez-Vázquez, Yaileen; Cabrera-Ríos, Mauricio
2014-01-01
Process windows in injection molding are habitually built with only one performance measure in mind. In reality, a more realistic picture can be obtained when considering multiple performance measures at a time, especially in the presence of conflict. In this work, the construction of process windows for injection molding (IM) is undertaken considering two and three performance measures in conflict simultaneously. The best compromises between the criteria involved are identified through the direct application of the concept of Pareto-dominance in multiple criteria optimization. The aim is to provide a formal and realistic strategy to set processing conditions in IM operations. The resulting optimization approach is easily implementable in MS Excel. The solutions are presented graphically to facilitate their use in manufacturing plants.
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Processing of sintered alpha SiC
NASA Technical Reports Server (NTRS)
Storm, R. S.
1984-01-01
Processing methods of sintered alpha SiC for engine applications are developed in a cost effective manner, using a submicron sized powder blended with sintering aids (boron and carbon). The processes for forming a green powder compact, such as dry pressing, cold isostatic pressing and green machining, slip casting, aqueous extrusion, plastic extrusion, and injection molding, are described. Dry pressing is the simplest route to component fabrication, and is carried out at approximately 10,000 psi pressure, while in the cold isostatic method the pressure could go as high as 20,000 psi. Surfactants are added to control settling rates and casting characteristics in the slip casting. The aqueous extrusion process is accomplished by a hydraulic ram forcing the aqueous mixture through a die. The plastic forming processes of extrusion and injection molding offer the potential of greater diversity in shape capacity. The physical properties of sintered alpha SiC (hardness, Young's modulus, shear modulus, and thermal diffusivity) are extensively tested. Corrosion resistance test results of silicon carbide are included.
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Method for preparing dosimeter for measuring skin dose
Jones, Donald E.; Parker, DeRay; Boren, Paul R.
1982-01-01
A personnel dosimeter includes a plurality of compartments containing thermoluminescent dosimeter phosphors for registering radiation dose absorbed in the wearer's sensitive skin layer and for registering more deeply penetrating radiation. Two of the phosphor compartments communicate with thin windows of different thicknesses to obtain a ratio of shallowly penetrating radiation, e.g. beta. A third phosphor is disposed within a compartment communicating with a window of substantially greater thickness than the windows of the first two compartments for estimating the more deeply penetrating radiation dose. By selecting certain phosphors that are insensitive to neutrons and by loading the holder material with neutron-absorbing elements, energetic neutron dose can be estimated separately from other radiation dose. This invention also involves a method of injection molding of dosimeter holders with thin windows of consistent thickness at the corresponding compartments of different holders. This is achieved through use of a die insert having the thin window of precision thickness in place prior to the injection molding step.
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Effects of powder characteristics on injection molding and burnout cracking
DOE Office of Scientific and Technical Information (OSTI.GOV)
Bandyopadhyay, G.; French, K.W.
Silicon nitride particle size and size distributions were varied widely to determine their effects on burnout cracking of injection-molded test parts containing thick and thin sections. Elimination of internal cracking required significant burnout shrinkage, which did not occur by changes of particle size and size distribution. However, isopressing of test parts after burnout provided the dimensional shrinkage necessary for producing crack-free components.
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Electrolyzer assembly method and system
Swala, Dana Ray; Bourgeois, Richard Scott; Paraszczak, Steven; Buckley, Donald Joseph
2017-05-23
The present techniques provide a novel electrolyzer and methods for welding components of such electrolyzers. The techniques may use conductors, such as resistance wires, placed in paths around the internal structural features and edges of the components. The conductors may be incorporated into the components during manufacture by injection molding, or other molding techniques, or may be tacked or otherwise applied to the surface of the components after manufacture. When current, a field or other excitation is applied to the conductors, the plastic surrounding the wire is melted. If this plastic is in direct contact with an adjoining component, a strong, hermetic seal may be formed between the two components, including the internal structural features.
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Natural Fiber Composite Retting, Preform Manufacture and Molding (Project 18988/Agreement 16313)
DOE Office of Scientific and Technical Information (OSTI.GOV)
Simmons, Kevin L.; Howe, Daniel T.; Laddha, Sachin
2009-12-31
Plant-based natural fibers can be used in place of glass in fiber reinforced automotive composites to reduce weight, cost and provide environmental benefits. Current automotive applications use natural fibers in injection molded thermoplastics for interior, non-structural applications. Compression molded natural fiber reinforced thermosets have the opportunity to extend natural fiber composite applications to structural and semi-structural parts and exterior parts realizing further vehicle weight savings. The development of low cost molding and fiber processing techniques for large volumes of natural fibers has helped in understanding the barriers of non-aqueous retting. The retting process has a significant effect on the fibermore » quality and its processing ability that is related to the natural fiber composite mechanical properties. PNNL has developed a compression molded fiber reinforced composite system of which is the basis for future preforming activities and fiber treatment. We are using this process to develop preforming techniques and to validate fiber treatment methods relative to OEM provided application specifications. It is anticipated for next fiscal year that demonstration of larger quantities of SMC materials and molding of larger, more complex components with a more complete testing regimen in coordination with Tier suppliers under OEM guidance.« less
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Organic materials for ceramic molding processes
NASA Technical Reports Server (NTRS)
Saito, K.
1984-01-01
Ceramic molding processes are examined. Binders, wetting agents, lubricants, plasticizers, surface active agents, dispersants, etc., for pressing, rubber pressing, sip casting, injection casting, taping, extrusion, etc., are described, together with forming machines.
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Liquid Crystalline Thermosets from Ester, Ester-Imide, and Ester-Amide Oligomers
NASA Technical Reports Server (NTRS)
Dingemans, Theodornus J. (Inventor); Weiser, Erik S. (Inventor); SaintClair, Terry L. (Inventor)
2005-01-01
Main chain thermotropic liquid crystal esters, ester-imides, and ester-amides were prepared from AA, BB, and AB type monomeric materials and were end-capped with phenylacetylene, phenylmaleimide, or nadimide reactive end-groups. The resulting reactive end-capped liquid crystal oligomers exhibit a variety of improved and preferred physical properties. The end-capped liquid crystal oligomers are thermotropic and have, preferably, molecular weights in the range of approximately 1000-15,OOO grams per mole. The end-capped liquid crystal oligomers have broad liquid crystalline melting ranges and exhibit high melt stability and very low melt viscosities at accessible temperatures. The end-capped liquid crystal oligomers are stable for up to an hour in the melt phase. These properties make the end-capped liquid crystal oligomers highly processable by a variety of melt process shape forming and blending techniques including film extrusion, fiber spinning, reactive injection molding (RIM), resin transfer molding (RTM), resin film injection (RFI), powder molding, pultrusion, injection molding, blow molding, plasma spraying and thermo-forming. Once processed and shaped, the end- capped liquid crystal oligomers were heated to further polymerize and form liquid crystalline thermosets (LCT). The fully cured products are rubbers above their glass transition temperatures. The resulting thermosets display many properties that are superior to their non-end-capped high molecular weight analogs.
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Liquid crystalline thermosets from ester, ester-imide, and ester-amide oligomers
NASA Technical Reports Server (NTRS)
Dingemans, Theodorous J. (Inventor); Weiser, Erik S. (Inventor); St. Clair, Terry L. (Inventor)
2005-01-01
Main chain thermotropic liquid crystal esters, ester-imides, and ester-amides were prepared from AA, BB, and AB type monomeric materials and were end-capped with phenylacetylene, phenylmaleimide, or nadimide reactive end-groups. The resulting reactive end-capped liquid crystal oligomers exhibit a variety of improved and preferred physical properties. The end-capped liquid crystal oligomers are thermotropic and have, preferably, molecular weights in the range of approximately 1000-15,000 grams per mole. The end-capped liquid crystal oligomers have broad liquid crystalline melting ranges and exhibit high melt stability and very low melt viscosities at accessible temperatures. The end-capped liquid crystal oligomers are stable for up to an hour in the melt phase. These properties make the end-capped liquid crystal oligomers highly processable by a variety of melt process shape forming and blending techniques including film extrusion, fiber spinning, reactive injection molding (RIM), resin transfer molding (RTM), resin film injection (RFI), powder molding, pultrusion, injection molding, blow molding, plasma spraying and thermo-forming. Once processed and shaped, the end-capped liquid crystal oligomers were heated to further polymerize and form liquid crystalline thermosets (LCT). The fully cured products are rubbers above their glass transition temperatures. The resulting thermosets display many properties that are superior to their non-end-capped high molecular weight analogs.
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Flow Kills Conductivity of Single Wall Carbon Nanotubes (SWNT) Composites
NASA Astrophysics Data System (ADS)
Bhatt, Sanjiv; Macosko, Christopher
2006-03-01
Most composites of polymer and single wall carbon nanotubes (SWNT) reported in the literature are made by solvent casting or simple compression molding. Commercial utility of these composites requires use of precision injection molding. We have observed a unique behavior wherein the SWNT composites made by injection molding or by extrusion are insulators but upon heating become electrically conductive. This behavior appears to be the result of a relaxation phenomenon in the SWNT composite. During flow into an injection mold or through an extrusion die the well-dispersed SWNT in the polymer matrix tend to align such that they are not in contact with each other and are farther than the minimum required distance, 5 nm (1), to achieve electrical percolation through electron hopping. Upon heating the SWNT relax and either touch each other or are at a distance less than or equal to 5 nm from each other to create a percolating. [1] Du, F., Scogna, R, C., Zhou, W., Brand, Stijn, Fischer, J. E., and Winey, K. I., Macromolecules 2004, 37, 9048-9055.
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Nadir Ayrilmis; Turgay Akbulut; Turker Dundar; Robert H. White; Fatih Mengeloglu; Zeki Candan; Umit Buyuksari; Erkan Avci
2011-01-01
Physical, mechanical, and fire properties of the injection-molded wood flour/polypropylene composites (WPCs) incorporated with different levels of boron compounds, borax/boric acid (BX/BA) (0.5:0.5 wt %) and zinc borate (ZB) (4, 8, or 12 wt %) were investigated. The effect of the coupling agent loading (2, 4, or 6 wt %), maleic anhydride-grafted PP (MAPP), on the...
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Tensile Characterization of Injection-Molded Fuzzy Glass Fiber/Nylon Composite Material
2016-05-01
enhanced reinforcement ( CER ) in a nylon matrix. A majority of the masterbatch CER material research is focused on electromagnetic shielding applications...however, the CER system, with the CNT network fixed to the host fiber, provides a novel approach of minimizing CNT agglomeration. Tensile specimens are...injection molded with varying weight percentages of CER to evaluate effect of the reinforcement on the mechanical properties. Tension testing showed
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Cruz, Heidy; Son, Younggon
2018-02-01
Since the discovery of carbon nanotubes (CNT), significant research works have focused on the application of CNT as conductive filler to polymer nanocomposites which can be used in several fields such as electrostatic dissipation (ESD), electrostatic painting and electromagnetic interference shielding (EMI-shielding). However, the main challenge in the large-scale manufacturing of this technology is the poor electrical conductivity of polymer nanocomposites produced by injection molding process. This study aims to investigate the effect of CNT aspect ratio in improving the electrical conductivity of injection molded nanocomposites. In this work, three types of multiwall carbon nanotubes with different lengths were melt-mixed with polycarbonate in a twin screw extruder followed by injection and compression molding. Results show that nanocomposites with higher CNT aspect ratio exhibit higher electrical conductivity. Longer nanotubes form a stronger conductive network during secondary agglomeration which can withstand the high shear forces during injection molding. Higher melt viscosity and storage modulus were observed in nanocomposites with higher CNT aspect ratio which is attributed to the effective constriction of polymer chains by longer nanotubes. It was also found that Tg of the composites increased with nanotube aspect ratio and the addition of CNT causes degradation which leads to the general Tg depression of polycarbonate.
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Mechanical properties of injection-molded thermoplastic denture base resins.
Hamanaka, Ippei; Takahashi, Yutaka; Shimizu, Hiroshi
2011-03-01
To investigate the mechanical properties of injection-molded thermoplastic denture base resins. Four injection-molded thermoplastic resins (two polyamides, one polyethylene terephthalate, one polycarbonate) and, as a control, a conventional heat-polymerized polymethyl methacrylate (PMMA), were used in this study. The flexural strength at the proportional limit (FS-PL), the elastic modulus, and the Charpy impact strength of the denture base resins were measured according to International Organization for Standardization (ISO) 1567 and ISO 1567:1999/Amd 1:2003. The descending order of the FS-PL was: conventional PMMA > polyethylene terephthalate, polycarbonate > two polyamides. The descending order of the elastic moduli was: conventional PMMA > polycarbonate > polyethylene terephthalate > two polyamides. The descending order of the Charpy impact strength was: polyamide (Nylon PACM12) > polycarbonate > polyamide (Nylon 12), polyethylene terephthalate > conventional PMMA. All of the injection-molded thermoplastic resins had significantly lower FS-PL, lower elastic moduli, and higher or similar impact strength compared to the conventional PMMA. The polyamide denture base resins had low FS-PL and low elastic moduli; one of them possessed very high impact strength, and the other had low impact strength. The polyethylene terephthalate denture base resin showed a moderately high FS-PL, moderate elastic modulus, and low impact strength. The polycarbonate denture base resin had a moderately high FS-PL, moderately high elastic modulus, and moderate impact strength.
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NASA Astrophysics Data System (ADS)
Han, Jun Sae; Gal, Chang Woo; Park, Jae Man; Kim, Jong Hyun; Park, Seong Jin
2018-04-01
Aspect ratio effects in the micro-powder injection molding process were experimentally analyzed for fabrication of high-aspect-ratio piezoelectric ceramic structure. The mechanisms of critical defects have been studied according to individual manufacturing steps. In the molding process, incomplete filling phenomenon determines the critical aspect ratios of a micro pattern. According to mold temperature, an incomplete filling phenomenon has been analyzed with respect to different pattern sizes and aspect ratio. In demolding and drying process, the capillary behavior of sacrificial polymeric mold insert determines the critical aspect ratio of a micro pattern. With respect to pattern dimensions, slumping behavior has been analyzed. Based on our current systems, micro PZT feature has stability when it has lower aspect ratio than 5. Under optimized processing conditions, 20 μm and 40 μm ceramic rod array feature which has 5 of aspect ratio were successfully fabricated by the developed process. Further modification points to fabricate the smaller and higher feature were specifically addressed.
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Method for forming glass-to-metal seals
Kramer, Daniel P.; Massey, Richard T.
1986-01-01
A method for forming a glass-to-metal seal in which the glass has a higher melting point than the metal. The molten glass is vacuum injection molded onto the metal, thus melting a very thin layer of the surface of the metal long enough to form a seal, but not long enough to cause a distortion in the shape of the metal component.
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NASA Technical Reports Server (NTRS)
Wiesner, Valerie L.; Youngblood, Jeffrey; Trice, Rodney
2014-01-01
Room-temperature injection molding is proposed as a novel, low-cost and more energy efficient manufacturing process capable of forming complex-shaped zirconium diboride (ZrB2) parts. This innovative processing method utilized aqueous suspensions with high powder loading and a minimal amount (5 vol.) of water-soluble polyvinylpyrrolidone (PVP), which was used as a viscosity modifier. Rheological characterization was performed to evaluate the room-temperature flow properties of ZrB2-PVP suspensions. ZrB2 specimens were fabricated with high green body strength and were machinable prior to binder removal despite their low polymer content. After binder burnout and pressureless sintering, the bulk density and microstructure of specimens were characterized using Archimedes technique and scanning electron microscopy. X-Ray Diffraction was used to determine the phase compositions present in sintered specimens. Ultimate strength of sintered specimens will be determined using ASTM C1323-10 compressive C-ring test.
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Chen, Hao; Sago, Alan; West, Shari; Farina, Jeff; Eckert, John; Broadley, Mark
2011-01-01
We present a comparative analysis between biocompatibility test results of wrought and Metal Injection Molded (MIM) ASTM F562-02 UNS R30035 (MP35N) and F1537 UNS R31538 (CCM) alloy samples that have undergone the same generic orthopedic implant's mechanical, chemical surface pre-treatment, and a designed pre-testing sample preparation method. Because the biocompatibility properties resulting from this new MIM cobalt alloy process are not well understood, we conducted tests to evaluate cytotoxicity (in vitro), hemolysis (in vitro), toxicity effects (in vivo), tissue irritation level (in vivo), and pyrogenicity count (in vitro) on such samples. We show that our developed MIM MP35N and CCM materials and treatment processes are biocompatible, and that both the MIM and wrought samples, although somewhat different in microstructure and surface, do not show significant differences in biocompatibility.
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NASA Astrophysics Data System (ADS)
Vélez-García, Gregorio M.; Ortman, Kevin C.; Eberle, Aaron P. R.; Wapperom, Peter; Baird, Donald G.
2008-07-01
A 2D coupled Hele-Shaw flow approximation for predicting the flow-induced orientation of high aspect ratio particles in injection molded composite parts is presented. For a highly concentrated short glass fiber PBT suspension, the impact of inter-particle interactions and the orientation at the gate is investigated for a center-gated disk using material parameters determined from rheometry. Experimental orientation is determined from confocal laser micrographs using the methods of ellipses. The constitutive equations are discretized using discontinuous Galerkin Finite Elements. Model predictions are significantly improved by using a localized orientation measured experimentally at the gate region instead of random or averaged gapwise measured orientation assumed in previous studies. The predicted profile in different radial positions can be related to the layered structure along the gapwise direction. Model modifications including interactions have lower impact than the initial conditions.
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Production of al-si alloy feedstocks using the solvent hot mixing method
NASA Astrophysics Data System (ADS)
Ni, J. Q.; Han, K. Q.; Yu, M. H.
2018-05-01
Powder injection molding is a promising low-cost technique for net shape processing of metal and ceramic components. This study aimed to investigate a new method for preparing aluminium (Al) – silicon (Si) alloy feedstock using the solvent hot mixing process. For this purpose, micron-sized Al-Si (20 wt. %) alloy powder was mixed with a binder consisting of 55 wt. % carnauba wax, 45 wt. % high-density polyethylene, and 3 wt. % stearic acid in a hot xylene bath. The scanning electron microscopy technique, thermogravimetric analysis, density measurement and torque measurements were used to verify the homogeneity of the feedstock. Moreover, the feedstock was chosen to perform the molding, debinding cycle and sintering. An Al-Si (20 wt. %) alloy part was successfully produced using this new method.
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NASA Astrophysics Data System (ADS)
Palcevskis, E.; Faitelson, L.; Jakobsons, E.
2005-05-01
The rheological properties of molding suspensions of alumina nanopowder in paraffin have been studied. Powders with specific surface areas of 32 and 55 m2/g and the surface-active substances oleic acid and Hypermer LP1 were used. The Hamaker constant for alumina particles in paraffin wax was estimated. A rough calculation showed that a gel should arise in the suspensions studied. The linearly viscoelastic characteristics determined by the method of small-amplitude periodic shear (on the frequency range from 0.063 to 157 s-1) confirmed this conclusion. The flow curves of the molding feedstock, determined over a broad range of shear rates (from 0.018 to 1070 s-1), point to a pseudoplastic character of the flow. From the rheological studies it follows that, in manufacturing engineering ceramics by injection molding from the suspensions investigated and in designing or selecting the forming equipment, the realization of maximum high shear strains must be ensured, which will promote a qualitative filling of intricately shaped and small-size molds.
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Injection molded polymer optics in the 21st Century
NASA Astrophysics Data System (ADS)
Beich, William S.
2005-08-01
Precision polymer optics, manufactured by injection molding techniques, has been a key enabling technology for several decades now. The technology, which can be thought of as a subset of the wider field of precision optics manufacturing, was pioneered in the United States by companies such as Eastman Kodak, US Precision Lens, and Polaroid. In addition to suppliers in the U.S. there are several companies worldwide that design and manufacture precision polymer optics, for example Philips High Tech Plastics in Europe and Fujinon in Japan. Designers who are considering using polymer optics need a fundamental understanding of exactly how the optics are created. This paper will survey the technology and processes that are employed in the successful implementation of a polymer optic solution from a manufacturer's perspective. Special emphasis will be paid to the unique relationship between the molds and the optics that they produce. We will discuss the key elements of production: molding resins, molds and molding equipment, and metrology. Finally we will offer a case study to illustrate just how the optics designer carries a design concept through to production. The underlying theme throughout the discussion of polymer optics is the need for the design team to work closely with an experienced polymer optics manufacturer with a solid track record of success in molded optics. As will be seen shortly, the complex interaction between thermoplastics, molds, and molding machines dictates the need for working closely with a supplier who has the critical knowledge needed to manage all aspects of the program.
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DOE Office of Scientific and Technical Information (OSTI.GOV)
Fang, Jun; Burghardt, Wesley R.; Bubeck, Robert A.
The development of molecular orientation in thermotropic liquid crystalline polymers (TLCPs) during injection molding has been investigated using two-dimensional wide-angle X-ray scattering coordinated with numerical computations employing the Larson-Doi polydomain model. Orientation distributions were measured in 'short shot' moldings to characterize structural evolution prior to completion of mold filling, in both thin and thick rectangular plaques. Distinct orientation patterns are observed near the filling front. In particular, strong extension at the melt front results in nearly transverse molecular alignment. Far away from the flow front shear competes with extension to produce complex spatial distributions of orientation. The relative influence ofmore » shear is stronger in the thin plaque, producing orientation along the filling direction. Exploiting an analogy between the Larson-Doi model and a fiber orientation model, we test the ability of process simulation tools to predict TLCP orientation distributions during molding. Substantial discrepancies between model predictions and experimental measurements are found near the flow front in partially filled short shots, attributed to the limits of the Hele-Shaw approximation used in the computations. Much of the flow front effect is however 'washed out' by subsequent shear flow as mold filling progresses, leading to improved agreement between experiment and corresponding numerical predictions.« less
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NASA Astrophysics Data System (ADS)
Garcia, Jose Luis
2000-10-01
In injection molding processes, computer aided engineering (CAE) allows processors to evaluate different process parameters in order to achieve complete filling of a cavity and, in some cases, it predicts shrinkage and warpage. However, because commercial computational packages are used to design complex geometries, detail in the thickness direction is limited. Approximations in the thickness direction lead to the solution of a 2½-D problem instead of a 3-D problem. These simplifications drastically reduce computational times and memory requirements. However, these approximations hinder the ability to predict thermal and/or mechanical degradation. The goal of this study was to determine the degree of degradation during PVC injection molding and to compare the results with a computational model. Instead of analyzing degradation in complex geometries, the computational analysis and injection molding trials were performed on typical sections found in complex geometries, such as flow in a tube, flow in a rectangular channel, and radial flow. This simplification reduces the flow problem to a 1-D problem and allows one to develop a computational model with a higher level of detail in the thickness direction, essential for the determination of degradation. Two different geometries were examined in this study: a spiral mold, in order to approximate the rectangular channel, and a center gated plate for the radial flow. Injection speed, melt temperature, and shot size were varied. Parts varying in degree of degradation, from no to severe degradation, were produced to determine possible transition points. Furthermore, two different PVC materials were used, low and high viscosity, M3800 and M4200, respectively (The Geon Company, Avon Lake, OH), to correlate the degree of degradation with the viscous heating observed during injection. It was found that a good agreement between experimental and computational results was obtained only if the reaction was assumed to be more thermally sensitive than found in literature. The results from this study show that, during injection, the activation energy for degradation was 65 kcal/mol, compared to 17--30 kcal/mol found in literature for quiescent systems.
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Three Dimensional Orientation Measurements in Liquid-Crystalline Polymers by FT-IR ATR Dichroism.
1987-07-24
dimension on an injection molded liquid crystalline copolyester plaque. This copolymer contains 75% of hydroxybenzoic acid (HBA) and 25% of 2,6...hydroxynaphthoic acid (HNA). Orientation functions were estimated averaging about a 10 u thick layer as a function of the location from the gate as well as the...molecular orientation in three dimension on an injection molded liquid crystalline copolyester plaque. This copolymer contains 75% of hydroxybenzoic acid
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Svečko, Rajko; Kusić, Dragan; Kek, Tomaž; Sarjaš, Andrej; Hančič, Aleš; Grum, Janez
2013-05-14
This paper presents an improved monitoring system for the failure detection of engraving tool steel inserts during the injection molding cycle. This system uses acoustic emission PZT sensors mounted through acoustic waveguides on the engraving insert. We were thus able to clearly distinguish the defect through measured AE signals. Two engraving tool steel inserts were tested during the production of standard test specimens, each under the same processing conditions. By closely comparing the captured AE signals on both engraving inserts during the filling and packing stages, we were able to detect the presence of macro-cracks on one engraving insert. Gabor wavelet analysis was used for closer examination of the captured AE signals' peak amplitudes during the filling and packing stages. The obtained results revealed that such a system could be used successfully as an improved tool for monitoring the integrity of an injection molding process.
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Svečko, Rajko; Kusić, Dragan; Kek, Tomaž; Sarjaš, Andrej; Hančič, Aleš; Grum, Janez
2013-01-01
This paper presents an improved monitoring system for the failure detection of engraving tool steel inserts during the injection molding cycle. This system uses acoustic emission PZT sensors mounted through acoustic waveguides on the engraving insert. We were thus able to clearly distinguish the defect through measured AE signals. Two engraving tool steel inserts were tested during the production of standard test specimens, each under the same processing conditions. By closely comparing the captured AE signals on both engraving inserts during the filling and packing stages, we were able to detect the presence of macro-cracks on one engraving insert. Gabor wavelet analysis was used for closer examination of the captured AE signals' peak amplitudes during the filling and packing stages. The obtained results revealed that such a system could be used successfully as an improved tool for monitoring the integrity of an injection molding process. PMID:23673677
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Investigation of interfacial fracture behavior on injection molded parts
NASA Astrophysics Data System (ADS)
Fischer, Matthieu; Ausias, Gilles; Kuehnert, Ines
2016-03-01
In this study the interfacial morphology of different polymers joined by various assembly injection molding (AIM) technologies were discussed. Melt streams were injected successively using tools with core-back or rotation techniques. To compare bulk specimen strength and weld line strength, the fracture behavior of different specimen scales and thin sections were investigated. An in-situ SEM tensile test and a new thin section testing device which is used in polarized (transmitted) light microscopy were used to observe specimen failure. The effects of processing on spherulitic structures were linked to bonding strength and mechanical properties.
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A Route for Polymer Nanocomposites with Engineered Electrical Conductivity and Percolation Threshold
Kalaitzidou, Kyriaki; Fukushima, Hiroyuki; Drzal, Lawrence T.
2010-01-01
Polymer nanocomposites with engineered electrical properties can be made by tuning the fabrication method, processing conditions and filler’s geometric and physical properties. This work focuses on investigating the effect of filler’s geometry (aspect ratio and shape), intrinsic electrical conductivity, alignment and dispersion within the polymer, and polymer crystallinity, on the percolation threshold and electrical conductivity of polypropylene based nanocomposites. The conductive reinforcements used are exfoliated graphite nanoplatelets, carbon black, vapor grown carbon fibers and polyacrylonitrile carbon fibers. The composites are made using melt mixing followed by injection molding. A coating method is also employed to improve the nanofiller’s dispersion within the polymer and compression molding is used to alter the nanofiller’s alignment.
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NASA Astrophysics Data System (ADS)
Roch, A.; Kehret, L.; Huber, T.; Henning, F.; Elsner, P.
2015-05-01
Investigations on PA6-GF50 integral foams have been carried out using different material systems: longfiber- and shortfiber-reinforced PA6 as well as unreinforced PA6 as a reference material. Both chemical and physical blowing agents were applied. Breathing mold technology (decompression of the mold) was selected for the foaming process. The integral foam design, which can be conceived as a sandwich structure, helps to save material in the neutral axis area and maintains a distance between load-bearing, unfoamed skin layers. For all test series an initial mold gap of 2.5 mm was chosen and the same amount of material was injected. In order to realize different density reductions, the mold opening stroke was varied. The experiments showed that, at a constant mass per unit area, integral polyamide 6 foams have a significantly higher bending stiffness than compact components, due to their higher area moment of inertia after foaming. At a constant surface weight the bending stiffness in these experiments could be increased by up to 600 %. Both shortfiber- and longfiber-reinforced polyamide 6 showed an increase in energy absorption during foaming.
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Turbine component casting core with high resolution region
Kamel, Ahmed; Merrill, Gary B.
2014-08-26
A hollow turbine engine component with complex internal features can include a first region and a second, high resolution region. The first region can be defined by a first ceramic core piece formed by any conventional process, such as by injection molding or transfer molding. The second region can be defined by a second ceramic core piece formed separately by a method effective to produce high resolution features, such as tomo lithographic molding. The first core piece and the second core piece can be joined by interlocking engagement that once subjected to an intermediate thermal heat treatment process thermally deform to form a three dimensional interlocking joint between the first and second core pieces by allowing thermal creep to irreversibly interlock the first and second core pieces together such that the joint becomes physically locked together providing joint stability through thermal processing.
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The use of image analysis in evaluation of the fibers orientation in Wood-polymer composites (WPC)
NASA Astrophysics Data System (ADS)
Bednarz, Arkadiusz; Frącz, Wiesław; Janowski, Grzegorz
2016-12-01
In this paper a novel way of a digital analysis of fibers orientation with a five-step algorithmwas presented. In the study, a molded piece with a dumbbell shape prepared from wood-polymer composite was used. The injection molding process was examined in experimental and numerical way. Based on the developed mathematical algorithm, a significant compliance of fiber orientation in different areas of the molded piece was obtained. The main aim of thisworkwas fiber orientation analysis of wood-polymer composites. An additional goal of thiswork was the comparison of the results reached in numerical analysis with results obtained from an experiment. The results of this research were important for the scientific and also from the practical point of view. In future works the prepared algorithm could be used to reach optimal parameters of the injection molding process.
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Wu, Linbo; Jing, Dianying; Ding, Jiandong
2006-01-01
A "room-temperature" injection molding approach combined with particulate leaching (RTIM/PL) has been, for the first time, developed in this work to fabricate three-dimensional porous scaffolds composed of biodegradable polyesters for tissue engineering. In this approach, a "wet" composite of particulate/polymer/solvent was used in processing, and thus the injection was not performed at melting state. Appropriate viscosity and flowability were facilely obtained at a certain solvent content so that the composite was able to be injected into a mould under low pressure at room temperature, which was very beneficial for avoiding thermal degradation of polyesters. As a demonstration, tubular and ear-shaped porous scaffolds were fabricated from biodegradable poly(D,L-lactide-co-glycolide) (PLGA) by this technology. Porosities of the resulting scaffolds were as high as 94%. The pores were well interconnected. Besides the well-known characteristics of injection molding to be suitable for automatization of a fabrication process with high repeatability and precision, this RTIM/PL approach is much suitable for tailoring highly porous foams with its advantages flexible for shaping complicated scaffolds, free of thermal degradation and high-pressure machine, etc.
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Bayraktaroglu, Esra; Gulsoy, H Ozkan; Gulsoy, Nagihan; Er, Ozay; Kilic, Hasan
2012-01-01
The research was investigated the effect of boron additions on sintering characteristics, mechanical, corrosion properties and biocompatibility of injection molded austenitic grade 316L stainless steel. Addition of boron is promoted to get high density of sintered 316L stainless steels. The amount of boron plays a role in determining the sintered microstructure and all properties. In this study, 316L stainless steel powders have been used with the elemental NiB powders. A feedstock containing 62.5 wt% powders loading was molded at different injection molded temperature. The binders were completely removed from molded components by solvent and thermal debinding at different temperature. The debinded samples were sintered at different temperature for 60 min. Mechanical property, microstructural characterization and electrochemical property of the sintered samples were performed using tensile testing, hardness, optical, scanning electron microscopy and electrochemical corrosion experiments. Sintered samples were immersed in a simulated body fluid (SBF) with elemental concentrations that were comparable to those of human blood plasma for a total period of 15 days. Both materials were implanted in fibroblast culture for biocompatibility evaluations were carried out. Results of study showed that sintered 316L and 316L with NiB addition samples exhibited high mechanical and corrosion properties in a physiological environment. Especially, 316L with NiB addition can be used in some bioapplications.
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Method for forming glass-to-metal seals
Kramer, D.P.; Massey, R.T.
1985-08-26
Disclosed is a method for forming a glass-to-metal seal in which the glass has a higher melting point than the metal. The molten glass is vacuum injection molded onto the metal, thus melting a very thin layer of the surface of the metal long enough to form a seal, but not long enough to cause a distortion in the shape of the metal component.
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NASA Astrophysics Data System (ADS)
Hafizzal, Y.; Nurulhuda, A.; Izman, S.; Khadir, AZA
2017-08-01
POM-copolymer bond breaking leads to change depending with respect to processing methodology and material geometries. This paper present the oversights effect on the material integrity due to different geometries and processing methodology. Thermo-analytical methods with reference were used to examine the degradation of thermomechanical while Thermogravimetric Analysis (TGA) was used to judge the thermal stability of sample from its major decomposition temperature. Differential Scanning Calorimetry (DSC) investigation performed to identify the thermal behaviour and thermal properties of materials. The result shown that plastic gear geometries with injection molding at higher tonnage machine more stable thermally rather than resin geometries. Injection plastic gear geometries at low tonnage machine faced major decomposition temperatures at 313.61°C, 305.76 °C and 307.91 °C while higher tonnage processing method are fully decomposed at 890°C, significantly higher compared to low tonnage condition and resin geometries specimen at 398°C. Chemical composition of plastic gear geometries with injection molding at higher and lower tonnage are compare based on their moisture and Volatile Organic Compound (VOC) content, polymeric material content and the absence of filler. Results of higher moisture and Volatile Organic Compound (VOC) content are report in resin geometries (0.120%) compared to higher tonnage of injection plastic gear geometries which is 1.264%. The higher tonnage of injection plastic gear geometry are less sensitive to thermo-mechanical degradation due to polymer chain length and molecular weight of material properties such as tensile strength, flexural strength, fatigue strength and creep resistance.
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Optimization of process parameters in the RF-DC plasma N2-H2 for AISI420 molds and dies
NASA Astrophysics Data System (ADS)
Herdianto, Hengky; Djoko, D. J.; Santjojo, H.; Masruroh
2017-11-01
The RF-DC plasma N2-H2 was used to make precise AISI420 molds and dies have complex textured geometry. The quality of the molds and dies directly affect the quality of the produced parts. The excellent examples of molds were used for injection molding lenses and dies used for the precision forging of automotive drive train components. In this study, a temperature, DC bias, and duration as process parameters of the RF-DC plasma N2-H2 have been optimized for molds and dies fabrication. The mask-less micro-patterned method was utilized to draw the initial 2D micro patterns directly onto the AISI420 substrate surface. The unprinted substrate surfaces were selectively nitrided by the RF-DC plasma N2-H2 at 673 K for 5400 s by 70 Pa with hollow cathode device. Energy Dispersive X-ray was utilized to describe the nitrogen content distribution at the vicinity of the border between the unprinted surfaces. This exclusive nitrogen mapping proves that only the unprinted parts of the substrate have high content nitrogen solutes. XRD analysis was performed to investigate whether the iron nitrides were precipitated by RF-DC plasma N2-H2 in the AISI420.
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Metal Injection Molding for Superalloy Jet Engine Components
2006-05-01
single vanes. The vanes are subject to high vibration stresses and thus require reliable fatigue strength. Therefore the quality of the material must meet...Injection Molding for Superalloy Jet Engine Components 9 - 12 RTO-MP-AVT-139 UNCLASSIFIED/UNLIMITED UNCLASSIFIED/UNLIMITED MTU AeroEngines copyright...Sikorski Max Kraus Dr. Claus Müller MTU Aero Engines GmbH Munich, Germany 15.05. - 17.05.2006 MTU AeroEngines copyright ©2 AVT – 139 on “Cost Effective
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DOE Office of Scientific and Technical Information (OSTI.GOV)
Nguyen, Ba Nghiep; Holbery, Jim; Smith, Mark T.
2006-11-30
This report describes the status of the current process modeling approaches to predict the behavior and flow of fiber-filled thermoplastics under injection molding conditions. Previously, models have been developed to simulate the injection molding of short-fiber thermoplastics, and an as-formed composite part or component can then be predicted that contains a microstructure resulting from the constituents’ material properties and characteristics as well as the processing parameters. Our objective is to assess these models in order to determine their capabilities and limitations, and the developments needed for long-fiber injection-molded thermoplastics (LFTs). First, the concentration regimes are summarized to facilitate the understandingmore » of different types of fiber-fiber interaction that can occur for a given fiber volume fraction. After the formulation of the fiber suspension flow problem and the simplification leading to the Hele-Shaw approach, the interaction mechanisms are discussed. Next, the establishment of the rheological constitutive equation is presented that reflects the coupled flow/orientation nature. The decoupled flow/orientation approach is also discussed which constitutes a good simplification for many applications involving flows in thin cavities. Finally, before outlining the necessary developments for LFTs, some applications of the current orientation model and the so-called modified Folgar-Tucker model are illustrated through the fiber orientation predictions for selected LFT samples.« less
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Interfacial crystalline structures in injection over-molded polypropylene and bond strength.
Yan, Bowen; Wu, Hong; Jiang, Genjie; Guo, Shaoyun; Huang, Jian
2010-11-01
This paper describes interfacial crystalline structures found in injection overmolded polypropylene components and the relationship of these structures to bond strength between the components. The combined effects of the development of hierarchical gradient structures and the particular thermomechanical environment near the interface on the interfacial crystalline structures were investigated in detail by PLM, SEM, DSC, WAXD, and infrared dichroism spectroscopy. The experimental results showed that during molding there was competitive formation of interfacial crystalline structures consisted of "shish-kebab" layer (SKL) and a transcrystalline layers (TCL). Variation in shear stress (controlled by injection pressure and injection speed) plays an important role in the formation of the SKL. The formation of TCL is influenced by the thermal environment, namely melt temperature and mold temperature. Increasing within certain limits, interfacial temperature and the thermal gradient near the interface promotes β-iPP growth. The relationship between interfacial crystalline structures and interfacial bond strength was established by lap shear measurement. The interfacial bond strength is improved by enhancing the formation of TCL, but reduced if SKL predominates.
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Verification of a two-dimensional infiltration model for the resin transfer molding process
NASA Technical Reports Server (NTRS)
Hammond, Vincent H.; Loos, Alfred C.; Dexter, H. Benson; Hasko, Gregory H.
1993-01-01
A two-dimensional finite element model for the infiltration of a dry textile preform by an injected resin was verified. The model, which is based on the finite element/control volume technique, determines the total infiltration time and the pressure increase at the mold inlet associated with the RTM process. Important input data for the model are the compaction and permeability behavior of the preform along with the kinetic and rheological behavior of the resin. The compaction behavior for several textile preforms was determined by experimental methods. A power law regression model was used to relate fiber volume fraction to the applied compaction pressure. Results showed a large increase in fiber volume fraction with the initial application of pressure. However, as the maximum fiber volume fraction was approached, the amount of compaction pressure required to decrease the porosity of the preform rapidly increased. Similarly, a power law regression model was used to relate permeability to the fiber volume fraction of the preform. Two methods were used to measure the permeability of the textile preform. The first, known as the steady state method, measures the permeability of a saturated preform under constant flow rate conditions. The second, denoted the advancing front method, determines the permeability of a dry preform to an infiltrating fluid. Water, corn oil, and an epoxy resin, Epon 815, were used to determine the effect of fluid type and viscosity on the steady state permeability behavior of the preform. Permeability values measured with the different fluids showed that fluid viscosity had no influence on the permeability behavior of 162 E-glass and TTI IM7/8HS preforms. Permeabilities measured from steady state and advancing front experiments for the warp direction of 162 E-glass fabric were similar. This behavior was noticed for tests conducted with corn oil and Epon 815. Comparable behavior was observed for the warp direction of the TTI IM7/8HS preform and corn oil. Mold filling and flow visualization experiments were performed to verify the analytical computer model. Frequency dependent electromagnetic sensors were used to monitor the resin flow front as a function of time. For the flow visualization tests, a video camera and high resolution tape recorder were used to record the experimental flow fronts. Comparisons between experimental and model predicted flow fronts agreed well for all tests. For the mold filling tests conducted at constant flow rate injection, the model was able to accurately predict the pressure increase at the mold inlet during the infiltration process. A kinetics model developed to predict the degree of cure as a function of time for the injected resin accurately calculated the increase in the degree of cure during the subsequent cure cycle.
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NASA Astrophysics Data System (ADS)
Liu, Lin; Wang, Xin-da; Li, Xiang; Qi, Xiao-tong; Qu, Xuan-hui
2017-09-01
The fabrication of 17-4PH micro spool mandrils by micro metal injection molding was described here. The effects of size reduction on deformation, microstructure and surface roughness were studied by comparing a ϕ500 μm micro post and a ϕ1.7 mm cylinder after debinding and sintering. Experimental results show that slumping of the micro posts occurred due to a dramatic increase in outlet vapor pressure initiated at the thermal degradation onset temperature and the moment of gravity. Asymmetrical stress distribution within the micro component formed during the cooling stage may cause warping. Prior solvent debinding and adjustment in a thermal debinding scheme were useful for preventing the deformation of the micro components. Smaller grain size and higher micro hardness due to impeded grain growth were observed for the micro posts compared with the ϕ1.7 mm cylinder. Surface roughness increased with distance from the gate of the micro spool mandril due to melt front advancement during mold filling and the ensuing pressure distribution. At each position, surface roughness was dictated by injection molding and increased slightly after sintering.
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Development and manufacture of visor for helmet-mounted display
NASA Astrophysics Data System (ADS)
Krevor, David H.; McNelly, Gregg; Skubon, John; Speirs, Robert
2004-01-01
The manufacturing design and process development for the Visor for the JHMCS (Joint Helmet Mounted Cueing System) are discussed. The JHMCS system is a Helmet Mounted Display (HMD) system currently flying on the F-15, F-16 and F/A-18 aircraft. The Visor manufacturing processes are essential to both system performance and economy. The Visor functions both as the system optical combiner and personal protective equipment for the pilot. The Visor material is optical polycarbonate. For a military HMD system, the mechanical and environmental properties of the Visor are as necessary as the optical properties. The visor must meet stringent dimensional requirements to assure adequate system optical performance. Injection molding can provide dimensional fidelity to the requirements, if done properly. Concurrent design of the visor and the tool (i.e., the injection mold) is essential. The concurrent design necessarily considers manufacturing operations and the use environment of the Visor. Computer modeling of the molding process is a necessary input to the mold design. With proper attention to product design and tool development, it is possible to improve upon published standard dimensional tolerances for molded polycarbonate articles.
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Design of Revolute Joints for In-Mold Assembly Using Insert Molding.
Ananthanarayanan, Arvind; Ehrlich, Leicester; Desai, Jaydev P; Gupta, Satyandra K
2011-12-01
Creating highly articulated miniature structures requires assembling a large number of small parts. This is a very challenging task and increases cost of mechanical assemblies. Insert molding presents the possibility of creating a highly articulated structure in a single molding step. This can be accomplished by placing multiple metallic bearings in the mold and injecting plastic on top of them. In theory, this idea can generate a multi degree of freedom structures in just one processing step without requiring any post molding assembly operations. However, the polymer material has a tendency to shrink on top of the metal bearings and hence jam the joints. Hence, until now insert molding has not been used to create articulated structures. This paper presents a theoretical model for estimating the extent of joint jamming that occurs due to the shrinkage of the polymer on top of the metal bearings. The level of joint jamming is seen as the effective torque needed to overcome the friction in the revolute joints formed by insert molding. We then use this model to select the optimum design parameters which can be used to fabricate functional, highly articulating assemblies while meeting manufacturing constraints. Our analysis shows that the strength of weld-lines formed during the in-mold assembly process play a significant role in determining the minimum joint dimensions necessary for fabricating functional revolute joints. We have used the models and methods described in this paper to successfully fabricate the structure for a minimally invasive medical robot prototype with potential applications in neurosurgery. To the best of our knowledge, this is the first demonstration of building an articulated structure with multiple degrees of freedom using insert molding.
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Multiple-Step Injection Molding for Fibrin-Based Tissue-Engineered Heart Valves
Weber, Miriam; Gonzalez de Torre, Israel; Moreira, Ricardo; Frese, Julia; Oedekoven, Caroline; Alonso, Matilde; Rodriguez Cabello, Carlos J.
2015-01-01
Heart valves are elaborate and highly heterogeneous structures of the circulatory system. Despite the well accepted relationship between the structural and mechanical anisotropy and the optimal function of the valves, most approaches to create tissue-engineered heart valves (TEHVs) do not try to mimic this complexity and rely on one homogenous combination of cells and materials for the whole construct. The aim of this study was to establish an easy and versatile method to introduce spatial diversity into a heart valve fibrin scaffold. We developed a multiple-step injection molding process that enables the fabrication of TEHVs with heterogeneous composition (cell/scaffold material) of wall and leaflets without the need of gluing or suturing components together, with the leaflets firmly connected to the wall. The integrity of the valves and their functionality was proved by either opening/closing cycles in a bioreactor (proof of principle without cells) or with continuous stimulation over 2 weeks. We demonstrated the potential of the method by the two-step molding of the wall and the leaflets containing different cell lines. Immunohistology after stimulation confirmed tissue formation and demonstrated the localization of the different cell types. Furthermore, we showed the proof of principle fabrication of valves using different materials for wall (fibrin) and leaflets (hybrid gel of fibrin/elastin-like recombinamer) and with layered leaflets. The method is easy to implement, does not require special facilities, and can be reproduced in any tissue-engineering lab. While it has been demonstrated here with fibrin, it can easily be extended to other hydrogels. PMID:25654448
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Multiple-Step Injection Molding for Fibrin-Based Tissue-Engineered Heart Valves.
Weber, Miriam; Gonzalez de Torre, Israel; Moreira, Ricardo; Frese, Julia; Oedekoven, Caroline; Alonso, Matilde; Rodriguez Cabello, Carlos J; Jockenhoevel, Stefan; Mela, Petra
2015-08-01
Heart valves are elaborate and highly heterogeneous structures of the circulatory system. Despite the well accepted relationship between the structural and mechanical anisotropy and the optimal function of the valves, most approaches to create tissue-engineered heart valves (TEHVs) do not try to mimic this complexity and rely on one homogenous combination of cells and materials for the whole construct. The aim of this study was to establish an easy and versatile method to introduce spatial diversity into a heart valve fibrin scaffold. We developed a multiple-step injection molding process that enables the fabrication of TEHVs with heterogeneous composition (cell/scaffold material) of wall and leaflets without the need of gluing or suturing components together, with the leaflets firmly connected to the wall. The integrity of the valves and their functionality was proved by either opening/closing cycles in a bioreactor (proof of principle without cells) or with continuous stimulation over 2 weeks. We demonstrated the potential of the method by the two-step molding of the wall and the leaflets containing different cell lines. Immunohistology after stimulation confirmed tissue formation and demonstrated the localization of the different cell types. Furthermore, we showed the proof of principle fabrication of valves using different materials for wall (fibrin) and leaflets (hybrid gel of fibrin/elastin-like recombinamer) and with layered leaflets. The method is easy to implement, does not require special facilities, and can be reproduced in any tissue-engineering lab. While it has been demonstrated here with fibrin, it can easily be extended to other hydrogels.
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NASA Astrophysics Data System (ADS)
Ginghtong, Thatchanok; Nakpathomkun, Natthapon; Pechyen, Chiravoot
2018-06-01
The parameters of the plastic injection molding process have been investigated for the manufacture of a 64 oz. ultra-thin polypropylene bucket. The 3 main parameters, such as injection speed, melting temperature, holding pressure, were investigated to study their effect on the physical appearance and compressive strength. The orthogonal array of Taguchi's L9 (33) was used to carry out the experimental plan. The physical properties were measured and the compressive strength was determined using linear regression analysis. The differential scanning calorimeter (DSC) was used to analyze the crystalline structure of the product. The optimization results show that the proposed approach can help engineers identify optimal process parameters and achieve competitive advantages of energy consumption and product quality. In addition, the injection molding of the product includes 24 mm of shot stroke, 1.47 mm position transfer, 268 rpm screw speed, injection speed 100 mm/s, 172 ton clamping force, 800 kgf holding pressure, 0.9 s holding time and 1.4 s cooling time, make the products in the shape and proportion of the product satisfactory. The parameters of influence are injection speed 71.07%, melting temperature 23.31% and holding pressure 5.62%, respectively. The compressive strength of the product was able to withstand a pressure of up to 839 N before the product became plastic. The low melting temperature was caused by the superior crystalline structure of the super-ultra-thin wall product which leads to a lower compressive strength.
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Tensile strength of various nylon PA6 specimen modes
NASA Astrophysics Data System (ADS)
Raz, Karel; Zahalka, Martin
2017-05-01
This article explores the influence of production technique on the strength of nylon parts. Identical specimens were manufactured by various techniques. The material of specimens was nylon PA6. 3D printing and injection molding were used, with various orientations of printed layers, and various orientations of specimens in the working space of the 3D printer. The variants are described in detail. A special mold was used for the injection molding process in order to make specimens with and without a weld line. The effect of this weld line was evaluated. All specimens were tested using the standard tensile test configuration. The strength was compared. It was found that the same plastic material has very different mechanical properties depending on the production process.
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Chaudhry, Anil R [Xenia, OH; Dzugan, Robert [Cincinnati, OH; Harrington, Richard M [Cincinnati, OH; Neece, Faurice D [Lyndurst, OH; Singh, Nipendra P [Pepper Pike, OH
2011-06-14
A foam material comprises a liquid polymer and a liquid isocyanate which is mixed to make a solution that is poured, injected or otherwise deposited into a corresponding mold. A reaction from the mixture of the liquid polymer and liquid isocyanate inside the mold forms a thermally collapsible foam structure having a shape that corresponds to the inside surface configuration of the mold and a skin that is continuous and unbroken. Once the reaction is complete, the foam pattern is removed from the mold and may be used as a pattern in any number of conventional casting processes.
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NASA Astrophysics Data System (ADS)
Weng, Can; Wang, Fei; Zhou, Mingyong; Yang, Dongjiao; Jiang, Bingyan
2018-04-01
A comparison of processes and wettability characteristics was presented for injection molded superhydrophobic polypropylene surfaces from two fabricating strategies. One is the biomimetic replication of patterns from indocalamus leaf in nature. The contact angle of water sitting on this PP surface was measured as 152 ± 2°, with comparable wetting behavior to natural indocalamus leaf surface. The other strategy is the fabrication of superhydrophobic structure by combining methods that produce structures at different length scales. Regarding both the machinability of mold inserts and function-oriented design, three micro-quadrangular arrays and one hierarchical micro-nano cylinder array were designed with the goal of superhydrophobicity. Particularly, a simple approach to the fabrication of hierarchical structures was proposed by combining the anodized plate and the punching plate. The function-oriented design targets as superhydrophobicity were all reached for the designed four structures. The measured contact angles of droplet for these structures were almost consistent with the calculated equilibrium contact angles from thermodynamic analysis. Among them, the contact angle of droplet on the surface of designed hierarchical structure reached about 163° with the sliding angle of 5°, resulting in self-cleaning characteristic. The superhydrophobicity of function-oriented designed polymer surfaces could be modified and controlled, which is exactly the limitation of replicating from natural organisms.
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Rheological and thermal performance of newly developed binder systems for ceramic injection molding
NASA Astrophysics Data System (ADS)
Hausnerova, Berenika; Kasparkova, Vera; Hnatkova, Eva
2016-05-01
In a novel binder system, carnauba wax was considered to replace the synthetic backbone polymers (polyolefins) enhancing the environmental sustainability of Ceramic Injection Molding (CIM) technology. The paper presents comparison of the rheological performance and thermal behavior of the aluminum oxide CIM feedstocks based on a binder containing carnauba wax with those consisting of a commercial binder. Further, acrawax (N, N'-Ethylene Bis-stearamide) has been considered as another possible substitute of polyolefins. For both proposed substitutes there is a significant reduction in viscosity, and in case of carnauba wax based feedstock also in processing temperature, which is essential for injection molding of reactive powders. Thermal characterization comprised analyses of single neat binders, their mixtures and mixtures with aluminum oxide. The presence of powder lowered melting temperatures of all tested binders except of polyolefin. Further depression in melting point of poly(ethylene glycol) is observed in combination with polyolefin in the presence of powder, and it is related to changes in size of the crystalline domains.
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Nagakura, Manamu; Tanimoto, Yasuhiro; Nishiyama, Norihiro
2017-07-26
The use of non-metal clasp denture (NMCD) materials may seriously affect the remaining tissues because of the low rigidity of NMCD materials such as polyamides. The purpose of this study was to develop a high-rigidity glass fiber-reinforced thermoplastic (GFRTP) composed of E-glass fiber and polyamide-6 for NMCDs using an injection molding. The reinforcing effects of fiber on the flexural properties of GFRTPs were investigated using glass fiber content ranging from 0 to 50 mass%. Three-point bending tests indicated that the flexural strength and elastic modulus of a GFRTP with a fiber content of 50 mass% were 5.4 and 4.7 times higher than those of unreinforced polyamide-6, respectively. The result showed that the physical characteristics of GFRTPs were greatly improved by increasing the fiber content, and the beneficial effects of fiber reinforcement were evident. The findings suggest that the injection-molded GFRTPs are adaptable to NMCDs because of their excellent mechanical properties.
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DOE Office of Scientific and Technical Information (OSTI.GOV)
Thi, Thanh Binh Nguyen, E-mail: nttbinh@kit.ac.jp; Yokoyama, Atsushi, E-mail: yokoyama@kit.ac.jp; Hamanaka, Senji
The theoretical fiber-interaction model for calculating the fiber orientation in the injection molded short fiber/thermoplastic composite parts was proposed. The proposed model included the fiber dynamics simulation in order to obtain an equation of the global interaction coefficient and accurate estimate of the fiber interacts at all orientation states. The steps to derive the equation for this coefficient in short fiber suspension as a function of the fiber aspect ratio, volume fraction and general shear rate are delineated. Simultaneously, the high-resolution 3D X-ray computed tomography system XVA-160α was used to observe fiber distribution of short-glass-fiber-reinforced polyamide specimens using different cavitymore » geometries. The fiber orientation tensor components are then calculated. Experimental orientation measurements of short-glass-fiber-reinforced polyamide is used to check the ability of present theory for predicting orientation. The experiments and predictions show a quantitative agreement and confirm the basic understanding of fiber orientation in injection-molded composites.« less
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Development and Design of Binder Systems for Titanium Metal Injection Molding: An Overview
NASA Astrophysics Data System (ADS)
Wen, Guian; Cao, Peng; Gabbitas, Brian; Zhang, Deliang; Edmonds, Neil
2013-03-01
Titanium metal injection molding (Ti-MIM) has been practiced since the late 1980s. Logically, the Ti-MIM practice follows the similar processes developed for the antecedent materials such as stainless steel and ceramics. Although Ti-MIM is a favorite research topic today, the issue of convincing the designers to use Ti injection-molded parts still exists. This is mainly because of the concern about contamination which seems unavoidable during the Ti-MIM process. Much information about the binder formulation, powder requirements, debinding, and sintering is available in the literature. There are several powder vendors and feedstock suppliers. However, most of the binders in the feedstock are proprietarily protected. The disclosed information on the binders used for formulating powder feedstock is very limited, which in turn discourages their adoption by engineering designers. This overview intends to discuss some of major binder systems for Ti-MIM available in the literature. It serves to provide a guideline for the Ti-MIM practitioners to choose a suitable powder feedstock.
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NASA Astrophysics Data System (ADS)
Thi, Thanh Binh Nguyen; Yokoyama, Atsushi; Hamanaka, Senji; Yamashita, Katsuhisa; Nonomura, Chisato
2016-03-01
The theoretical fiber-interaction model for calculating the fiber orientation in the injection molded short fiber/thermoplastic composite parts was proposed. The proposed model included the fiber dynamics simulation in order to obtain an equation of the global interaction coefficient and accurate estimate of the fiber interacts at all orientation states. The steps to derive the equation for this coefficient in short fiber suspension as a function of the fiber aspect ratio, volume fraction and general shear rate are delineated. Simultaneously, the high-resolution 3D X-ray computed tomography system XVA-160α was used to observe fiber distribution of short-glass-fiber-reinforced polyamide specimens using different cavity geometries. The fiber orientation tensor components are then calculated. Experimental orientation measurements of short-glass-fiber-reinforced polyamide is used to check the ability of present theory for predicting orientation. The experiments and predictions show a quantitative agreement and confirm the basic understanding of fiber orientation in injection-molded composites.
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Low-cost conformable storage to maximize vehicle range
DOE Office of Scientific and Technical Information (OSTI.GOV)
Graham, R.P.
Liquefied petroleum gas (LPG) and compressed natural gas (CNG) are currently the leading fuel contenders for converting vehicles from gasoline and diesel to alternative fuels. Two factors that inhibit conversion are additional vehicle costs and reduced range compared to gasoline. In overcoming these barriers, a key element of the alternative fuel system becomes the storage tank for these pressurized fuels. Using cylindrical pressure vessels is the conventional approach, but they do not package well in the available vehicle volume. Thiokol Corporation has developed and is now producing a conformable (non-cylindrical) aluminum storage system for LPG vans. This system increases fuelmore » storage in a given rectangular envelope. The goal of this project was to develop the technology for a lower cost conformable tank made of injection-molded plastic. Much of the cost of the aluminum conformable tank is in the fabrication because several weld seams are required. The injection-molding process has the potential to greatly reduce the fabrication costs. The requirements of a pressurized fuel tank on a vehicle necessitate the proper combination of material properties. Material selection and tank design must be optimized for maximum internal volume and minimum material use to be competitive with other technologies. The material and the design must also facilitate the injection-molding process. Prototype tanks must be fabricated to reveal molding problems, prove solutions, and measure results. In production, efficient fabrication will be key to making these tanks cost competitive. The work accomplished during this project has demonstrated that conformable LPG tanks can be molded with thermoplastics. However, to achieve a competitive tank, improvements are needed in the effective material strength. If these improvements can be made, molded plastics should produce a lower cost tank that can store more LPG on a vehicle than conventional cylinders.« less
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Ion channel recordings on an injection-molded polymer chip.
Tanzi, Simone; Matteucci, Marco; Christiansen, Thomas Lehrmann; Friis, Søren; Christensen, Mette Thylstrup; Garnaes, Joergen; Wilson, Sandra; Kutchinsky, Jonatan; Taboryski, Rafael
2013-12-21
In this paper, we demonstrate recordings of the ion channel activity across the cell membrane in a biological cell by employing the so-called patch clamping technique on an injection-molded polymer microfluidic device. The findings will allow direct recordings of ion channel activity to be made using the cheapest materials and production platform to date and with the potential for very high throughput. The employment of cornered apertures for cell capture allowed the fabrication of devices without through holes and via a scheme comprising master origination by dry etching in a silicon substrate, electroplating in nickel and injection molding of the final part. The most critical device parameters were identified as the length of the patching capillary and the very low surface roughness on the inside of the capillary. The cross-sectional shape of the orifice was found to be less critical, as both rectangular and semicircular profiles seemed to have almost the same ability to form tight seals with cells with negligible leak currents. The devices were functionally tested using human embryonic kidney cells expressing voltage-gated sodium channels (Nav1.7) and benchmarked against a commercial state-of-the-art system for automated ion channel recordings. These experiments considered current-voltage (IV) relationships for activation and inactivation of the Nav1.7 channels and their sensitivity to a local anesthetic, lidocaine. Both IVs and lidocaine dose-response curves obtained from the injection-molded polymer device were in good agreement with data obtained from the commercial system.
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Anisotropic mechanical behavior of an injection molded short fiber reinforced thermoplastic
NASA Astrophysics Data System (ADS)
Lopez, Delphine; Thuillier, Sandrine; Bessières, Nicolas; Grohens, Yves
2016-10-01
A short fiber reinforced thermoplastic was injected into a rectangular mold, in order to prepare samples to characterize the mechanical behavior of the material. The injection process was simulated with Moldflow and a cutting pattern was deduced from the predicted fiber orientation, leading to samples with several well-defined orientations with respect to the injection direction. Monotonic tensile tests up to rupture, as well as complex cycles made of loading steps followed by relaxation steps at different strain levels were performed, in order to check the reproducibility for a given orientation. Moreover, the fiber orientation in the central part of the tensile samples was also analyzed with X-ray tomography. The results show that the mechanical behavior for each orientation (among 6) was rather reproducible, thus validating the cutting pattern.
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NASA Astrophysics Data System (ADS)
Ayad, G.; Song, J.; Barriere, T.; Liu, B.; Gelin, J. C.
2007-05-01
The paper is concerned with optimization and parametric identification of Powder Injection Molding process that consists first in injection of powder mixture with polymer binder and then to the sintering of the resulting powders parts by solid state diffusion. In the first part, one describes an original methodology to optimize the injection stage based on the combination of Design Of Experiments and an adaptive Response Surface Modeling. Then the second part of the paper describes the identification strategy that one proposes for the sintering stage, using the identification of sintering parameters from dilatometer curves followed by the optimization of the sintering process. The proposed approaches are applied to the optimization for manufacturing of a ceramic femoral implant. One demonstrates that the proposed approach give satisfactory results.
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Nano Petri dishes: a new polystyrene platform for studying cell-nanoengineered surface interactions
NASA Astrophysics Data System (ADS)
Cha, Kyoung Je; Na, Moon-Hee; Kim, Hyung Woo; Kim, Dong Sung
2014-05-01
In this study, we fabricated and fully characterized a new type of polystyrene (PS) cell-culture platform containing nanoengineered surfaces (NES), referred to as a nano Petri dish, which can be used at the transition stage of basic cell-NES interaction studies for clinical applications. Nano-injection molding in this study was used for the mass production of the nano Petri dish having nanopore arrays. The effects of processing parameters of the injection molding on the replication quality of the nanopore arrays were quantitatively evaluated by means of design of experiments based on the Taguchi method. This allowed efficient and reliable cell culture studies by providing large numbers of the same dishes, in addition to removing the fixation step of the NES plates inside the cell-culture container. Physical, chemical and mechanical properties of the NES, as well as cell behavior including attachment and proliferation of human osteosarcoma MG-63 cells on the NES, were then characterized, with and without the oxygen plasma surface treatment.
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Ceramic micro-injection molded nozzles for serial femtosecond crystallography sample delivery
NASA Astrophysics Data System (ADS)
Beyerlein, K. R.; Adriano, L.; Heymann, M.; Kirian, R.; Knoška, J.; Wilde, F.; Chapman, H. N.; Bajt, S.
2015-12-01
Serial femtosecond crystallography (SFX) using X-ray Free-Electron Lasers (XFELs) allows for room temperature protein structure determination without evidence of conventional radiation damage. In this method, a liquid suspension of protein microcrystals can be delivered to the X-ray beam in vacuum as a micro-jet, which replenishes the crystals at a rate that exceeds the current XFEL pulse repetition rate. Gas dynamic virtual nozzles produce the required micrometer-sized streams by the focusing action of a coaxial sheath gas and have been shown to be effective for SFX experiments. Here, we describe the design and characterization of such nozzles assembled from ceramic micro-injection molded outer gas-focusing capillaries. Trends of the emitted jet diameter and jet length as a function of supplied liquid and gas flow rates are measured by a fast imaging system. The observed trends are explained by derived relationships considering choked gas flow and liquid flow conservation. Finally, the performance of these nozzles in a SFX experiment is presented, including an analysis of the observed background.
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Improved silicon nitride for advanced heat engines
NASA Technical Reports Server (NTRS)
Yeh, H. C.; Wimmer, J. M.; Huang, H. H.; Rorabaugh, M. E.; Schienle, J.; Styhr, K. H.
1985-01-01
The AiResearch Casting Company baseline silicon nitride (92 percent GTE SN-502 Si sub 3 N sub 4 plus 6 percent Y sub 2 O sub 3 plus 2 percent Al sub 2 O sub 3) was characterized with methods that included chemical analysis, oxygen content determination, electrophoresis, particle size distribution analysis, surface area determination, and analysis of the degree of agglomeration and maximum particle size of elutriated powder. Test bars were injection molded and processed through sintering at 0.68 MPa (100 psi) of nitrogen. The as-sintered test bars were evaluated by X-ray phase analysis, room and elevated temperature modulus of rupture strength, Weibull modulus, stress rupture, strength after oxidation, fracture origins, microstructure, and density from quantities of samples sufficiently large to generate statistically valid results. A series of small test matrices were conducted to study the effects and interactions of processing parameters which included raw materials, binder systems, binder removal cycles, injection molding temperatures, particle size distribution, sintering additives, and sintering cycle parameters.
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Powder Injection Molding for mass production of He-cooled divertor parts
NASA Astrophysics Data System (ADS)
Antusch, S.; Norajitra, P.; Piotter, V.; Ritzhaupt-Kleissl, H.-J.
2011-10-01
A He-cooled divertor for future fusion power plants has been developed at KIT. Tungsten and tungsten alloys are presently considered the most promising materials for functional and structural divertor components. The advantages of tungsten materials lie, e.g. in the high melting point, and low activation, the disadvantages are high hardness and brittleness. The machinig of tungsten, e.g. milling, is very complex and cost-intensive. Powder Injection Molding (PIM) is a method for cost effective mass production of near-net-shape parts with high precision. The complete W-PIM process route is outlined and, results of product examination discussed. A binary tungsten powder feedstock with a grain size distribution in the range 0.7-1.7 μm FSSS, and a solid load of 50 vol.% was developed. After heat treatment, the successfully finished samples showed promising results, i.e. 97.6% theoretical density, a grain size of approximately 5 μm, and a hardness of 457 HV0.1.
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Dosimeter for measuring skin dose and more deeply penetrating radiation
Jones, Donald E.; Parker, DeRay; Boren, Paul R.
1981-01-01
A personnel dosimeter includes a plurality of compartments containing thermoluminescent dosimeter phosphors for registering radiation dose absorbed in the wearer's sensitive skin layer and for registering more deeply penetrating radiation. Two of the phosphor compartments communicate with thin windows of different thicknesses to obtain a ratio of shallowly penetrating radiation, e.g. beta. A third phosphor is disposed within a compartment communicating with a window of substantially greater thickness than the windows of the first two compartments for estimating the more deeply penetrating radiation dose. By selecting certain phosphors that are insensitive to neutrons and by loading the holder material with netruon-absorbing elements, energetic neutron dose can be estimated separately from other radiation dose. This invention also involves a method of injection molding of dosimeter holders with thin windows of consistent thickness at the corresponding compartments of different holders. This is achieved through use of a die insert having the thin window of precision thickness in place prior to the injection molding step.
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Magnetic Properties of Rapid Cooled FeCoB Based Alloys Produced by Injection Molding
NASA Astrophysics Data System (ADS)
Nabialek, M.; Jeż, B.; Jeż, K.; Pietrusiewicz, P.; Gruszka, K.; Błoch, K.; Gondro, J.; Rzącki, J.; Abdullah, M. M. A. B.; Sandu, A. V.; Szota, M.
2018-06-01
The paper presents the results of investigations of the structure and magnetic properties of massive rapid cooled Fe50-xCo20+xB20Cu1Nb9 alloys (where x = 0, 5). Massive alloys were made using the method of injecting a liquid alloy into a copper mold. Samples were obtained in the form of 0.5 mm thick plates. The structure of the obtained samples was examined using an X-ray diffractometer equipped with a CuKα lamp. The phase composition of the alloys formed was determined using the Match program. By using Sherrer’s dependence the grain sizes of the identified crystalline phases were estimated. Using the Faraday magnetic balance, the magnetization of samples as a function of temperature in the range from room temperature to 850K was measured. Magnetization of saturation and value of the coercive field for the prepared alloys were determined on the basis of magnetic hysteresis loop measurement using the LakeShore vibration magnetometer.
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Tang, Hu; Chen, Jing-Bin; Wang, Yan; Xu, Jia-Zhuang; Hsiao, Benjamin S; Zhong, Gan-Ji; Li, Zhong-Ming
2012-11-12
The effect of shear flow and carbon nanotubes (CNTs), separately and together, on nonisothermal crystallization of poly(lactic acid) (PLA) at a relatively large cooling rate was investigated by time-resolved synchrotron wide-angle X-ray diffraction (WAXD) and polarized optical microscope (POM). Unlike flexible-chain polymers such as polyethylene, and so on, whose crystallization kinetics are significantly accelerated by shear flow, neat PLA only exhibits an increase in onset crystallization temperature after experiencing a shear rate of 30 s(-1), whereas both the nucleation density and ultimate crystallinity are not changed too much because PLA chains are intrinsically semirigid and have relatively short length. The breaking down of shear-induced nuclei into point-like precursors (or random coil) probably becomes increasingly active after shear stops. Very interestingly, a marked synergistic effect of shear flow and CNTs exists in enhancing crystallization of PLA, leading to a remarkable increase of nucleation density in PLA/CNT nanocomposite. This synergistic effect is ascribed to extra nuclei, which are formed by the anchoring effect of CNTs' surfaces on the shear-induced nuclei and suppressing effect of CNTs on the relaxation of the shear-induced nuclei. Further, this interesting finding was deliberately applied to injection molding, aiming to improve the crystallinity of PLA products. As expected, a remarkable high crystallinity in the injection-molded PLA part has been achieved successfully by the combination of shear flow and CNTs, which offers a new method to fabricate PLA products with high crystallinity for specific applications.
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Modeling of short fiber reinforced injection moulded composite
NASA Astrophysics Data System (ADS)
Kulkarni, A.; Aswini, N.; Dandekar, C. R.; Makhe, S.
2012-09-01
A micromechanics based finite element model (FEM) is developed to facilitate the design of a new production quality fiber reinforced plastic injection molded part. The composite part under study is composed of a polyetheretherketone (PEEK) matrix reinforced with 30% by volume fraction of short carbon fibers. The constitutive material models are obtained by using micromechanics based homogenization theories. The analysis is carried out by successfully coupling two commercial codes, Moldflow and ANSYS. Moldflow software is used to predict the fiber orientation by considering the flow kinetics and molding parameters. Material models are inputted into the commercial software ANSYS as per the predicted fiber orientation and the structural analysis is carried out. Thus in the present approach a coupling between two commercial codes namely Moldflow and ANSYS has been established to enable the analysis of the short fiber reinforced injection moulded composite parts. The load-deflection curve is obtained based on three constitutive material model namely an isotropy, transversely isotropy and orthotropy. Average values of the predicted quantities are compared to experimental results, obtaining a good correlation. In this manner, the coupled Moldflow-ANSYS model successfully predicts the load deflection curve of a composite injection molded part.
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Preparation and Characterization of PETI-330/Multiwalled Carbon Nanotube
NASA Technical Reports Server (NTRS)
Ghose, Sayata; Watson, Kent A.; Working, Dennis C.; Criss, Jim M.; Siochi, Emilie J.; Connell, John W.
2005-01-01
As part of an ongoing effort to incorporate multifunctionality into advanced composites, blends of PETI-330 and multi-walled carbon nanotubes (MWCNTs) were prepared, characterized and fabricated into moldings. The PETI-330/MWCNT mixtures were prepared at concentrations ranging from 3 to 25 weight percent by dry mixing the components in a ball mill. The resulting powders were characterized for degree of mixing, thermal and rheological properties. Based on the characterization results, PETI-330/MWCNT samples were scaled up to 300 g and used to fabricate moldings 10.2 cm x 15.2 cm x 0.32 cm thick. The moldings were made by injecting the mixtures at 260-280 C into an Invar tool followed by curing for 1 h at 371 C. The tool was designed to impart shear during the injection process in an attempt to achieve some alignment of the MWCNTs in the flow direction. Good quality moldings were obtained that were subsequently characterized for thermal, mechanical and electrical properties. The degree of dispersion and alignment of the MWCNTs were investigated using high-resolution scanning electron microscopy. The preparation and preliminary characterization of PETI-330/MWCNT composites will be discussed. Keywords: phenylethynyl terminated imides, high temperature polymers, nanocomposites, moldings
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Method for bonding a transmission line to a downhole tool
Hall, David R.; Fox, Joe
2007-11-06
An apparatus for bonding a transmission line to the central bore of a downhole tool includes a pre-formed interface for bonding a transmission line to the inside diameter of a downhole tool. The pre-formed interface includes a first surface that substantially conforms to the outside contour of a transmission line and a second surface that substantially conforms to the inside diameter of a downhole tool. In another aspect of the invention, a method for bonding a transmission line to the inside diameter of a downhole tool includes positioning a transmission line near the inside wall of a downhole tool and placing a mold near the transmission line and the inside wall. The method further includes injecting a bonding material into the mold and curing the bonding material such that the bonding material bonds the transmission line to the inside wall.
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NASA Technical Reports Server (NTRS)
Gilmore, Randy
1993-01-01
The ultrasonic polishing process makes use of the high-frequency (ultrasonic) vibrations of an abradable tool which automatically conforms to the work piece and an abrasive slurry to finish surfaces and edges on complex, highly detailed, close tolerance cavities in materials from beryllium copper to carbide. Applications range from critical deburring of guidance system components to removing EDM recast layers from aircraft engine components to polishing molds for forming carbide cutting tool inserts or injection molding plastics. A variety of materials including tool steels, carbides, and even ceramics can be successfully processed. Since the abradable tool automatically conforms to the work piece geometry, the ultrasonic finishing method described offers a number of important benefits in finishing components with complex geometries.
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Factors influencing microinjection molding replication quality
NASA Astrophysics Data System (ADS)
Vera, Julie; Brulez, Anne-Catherine; Contraires, Elise; Larochette, Mathieu; Trannoy-Orban, Nathalie; Pignon, Maxime; Mauclair, Cyril; Valette, Stéphane; Benayoun, Stéphane
2018-01-01
In recent years, there has been increased interest in producing and providing high-precision plastic parts that can be manufactured by microinjection molding: gears, pumps, optical grating elements, and so on. For all of these applications, the replication quality is essential. This study has two goals: (1) fabrication of high-precision parts using the conventional injection molding machine; (2) identification of robust parameters that ensure production quality. Thus, different technological solutions have been used: cavity vacuuming and the use of a mold coated with DLC or CrN deposits. AFM and SEM analyses were carried out to characterize the replication profile. The replication quality was studied in terms of the process parameters, coated and uncoated molds and crystallinity of the polymer. Specific studies were processed to quantify the replicability of injection molded parts (ABS, PC and PP). Analysis of the Taguchi experimental designs permits prioritization of the impact of each parameter on the replication quality. A discussion taking into account these new parameters and the thermal and spreading properties on the coatings is proposed. It appeared that, in general, increasing the mold temperature improves the molten polymer fill in submicron features except for the steel insert (for which the presence of a vacuum is the most important factor). Moreover, the DLC coating was the best coating to increase the quality of the replication. This result could be explained by the lower thermal diffusivity of this coating. We noted that the viscosity of the polymers is not a primordial factor of the replication quality.
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NASA Technical Reports Server (NTRS)
Bharwani, S. S.; Walls, J. T.; Jackson, M. E.
1987-01-01
A knowledge based system to assist process engineers in evaluating the processability and moldability of poly-isocyanurate (PIR) formulations for the thermal protection system of the Space Shuttle external tank (ET) is discussed. The Reaction Injection Molding- Process Development Advisor (RIM-PDA) is a coupled system which takes advantage of both symbolic and numeric processing techniques. This system will aid the process engineer in identifying a startup set of mold schedules and in refining the mold schedules to remedy specific process problems diagnosed by the system.
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Research on Protective Effect and Mechanism of Idazoxan on lps Attacked Acute Hepatic Injury
NASA Astrophysics Data System (ADS)
Zhu, Junyu; Ying, Shangqi; Kang, Wenyuan; Huang, Wenjuan; Liang, Huaping
2018-01-01
Objective: To observe the protection effect of Idazoxan (IDA) on LPS induced acute hepatic injury, and to explore its action mechanism. Methods: 60 adult C57BL/6 mice were divided into a control group (20 mice, intraperitoneal injection of phosphate buffer), a model group (20 mice, intraperitoneal injection of LPS 10 mg/kg) and a agmatine group (20 mice, intraperitoneal injection of LPS 10 mg/kg and agmatine 200 mg/kg) according to random number table method. Blood and liver tissue were collected for preparation of tissue homogenate. Enzyme-linked immunosorbent assay (ELISA) was adopted for detecting tumor necrosis factor-α (TNF-α) and interleukin (IL- 1β and IL - 6) contents in the serum and liver tissue at 24h after molding. Automatic biochemical analyzer is used for determining alanine transaminase (ALT), aspartate aminotransferase (AST) and lactate dehydrogenase (LDH) level at 24h after molding; The liver tissue pathology changes were observed at 24h after molding. Macrophage RAW264.7 cells were stimulated by 10 μg/mL LPS and with or without IDA (100 μmol/L). 2’, 7’-dichlorofluoresce in diacetate (DCFH-DA) was used as a fluorescent probe for detection of intracellular reactive oxygen species (ROS) level; qRT - PCR method was used for detecting antioxidant enzymes HO-1 and NQO-1 mRNA expression level at 2h, 4h and 8 h. Results: mice in the model group suffered from depression, curling and food water forbidding at 6h after molding. Mice in the Idazoxan group have obviously better spirit and activity than that of model group. The serum ALT, AST and LDH level of LPS attacked acute hepatic injury mice can be effectively alleviated after Idazoxan treatment. The expression of proinflammatory factor TNF-α and IL-6 in the liver can be reduced. The liver showed obvious pathological changes at 24 h after injection, such as liver cell swelling, necrosis, congestion, inflammatory cell infiltration, etc.; The liver cell injury was prominently alleviated in IDA treatment group. Compared with the control group, LPS significantly increased ROS level in RAW264.7 cells. The ROS level was decreased with concentration dependence after IDA intervention. IDA increased HO-1 mRNA expression of RAW264.7 cells. It had no influence on NQO-1mRNA. Conclusion: IDA significantly reduces the serum liver injury indexes and contents of TNF-α, IL-6 and other inflammatory mediators in liver tissues. It can alleviate the liver pathology change, thereby it can generate protection function on LPS attacked acute hepatic injury. Its action mechanism may be related to IDA-enhanced liver macrophage antioxidant function.
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40 CFR Table 8 to Subpart Wwww of... - Initial Compliance With Organic HAP Emissions Limits
Code of Federal Regulations, 2011 CFR
2011-07-01
... organic HAP emissions limit . . . You have demonstrated initial complianceif . . . 1. open molding and... contents. 2. open molding centrifugal casting, continuous lamination/casting, SMC and BMC manufacturing... die injection, and/or wet-area enclosures that meet the criteria of § 63.5830. 6. pultrusion...
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40 CFR Table 4 to Subpart Wwww of... - Work Practice Standards
Code of Federal Regulations, 2010 CFR
2010-07-01
.... a new or existing closed molding operation using compression/injection molding uncover, unwrap or... new or existing cleaning operation not use cleaning solvents that contain HAP, except that styrene may... contacts resin. 3. a new or existing materials HAP-containing materials storage operation keep containers...
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NASA Astrophysics Data System (ADS)
Mertus, Lou; Symmons, Alan
2012-10-01
In recent years, the trend within the molded optics community has been an overall advancement in the capability to diamond grind molds using a variety of grinding techniques. Improvements in grinding equipment, materials and tooling have enabled higher quality ceramic and carbide molds and thereby lenses. Diamond turned molds from ductile metals are still used prevalently throughout the molding industry. Each technology presents a unique set of advantages and disadvantages whether used for precision injection molding of plastic optics or precision glass molding. This paper reviews the manufacturing techniques for each approach and applicable molding process. The advantages and disadvantages of each are compared and analyzed. The subtle differences that exist in optics molded from each technique and the impact they have on the performance in various applications is reviewed. Differences stemming from tooling material properties, material-specific minor defects, as well as cutting and grinding process-induced artifacts are described in detail as well as their influence on the roughness, waviness, and form errors present on the molded surface. A comparison with results between similar surfaces for both diamond grinding and diamond turning is presented.
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Foam injection molding of elastomers with iron microparticles
NASA Astrophysics Data System (ADS)
Volpe, Valentina; D'Auria, Marco; Sorrentino, Luigi; Davino, Daniele; Pantani, Roberto
2015-12-01
In this work, a preliminary study of foam injection molding of a thermoplastic elastomer, Engage 8445, and its microcomposite loaded with iron particles was carried out, in order to evaluate the effect of the iron microparticles on the foaming process. In particular, reinforced samples have been prepared by using nanoparticles at 2% by volume. Nitrogen has been used as physical blowing agent. Foamed specimens consisting of neat and filled elastomer were characterized by density measurements and morphological analysis. While neat Engage has shown a well developed cellular morphology far from the injection point, the addition of iron microparticles considerably increased the homogeneity of the cellular morphology. Engage/iron foamed samples exhibited a reduction in density greater than 32%, with a good and homogeneous cellular morphology, both in the transition and in the core zones, starting from small distances from the injection point.
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Optimal Design of Material and Process Parameters in Powder Injection Molding
NASA Astrophysics Data System (ADS)
Ayad, G.; Barriere, T.; Gelin, J. C.; Song, J.; Liu, B.
2007-04-01
The paper is concerned with optimization and parametric identification for the different stages in Powder Injection Molding process that consists first in injection of powder mixture with polymer binder and then to the sintering of the resulting powders part by solid state diffusion. In the first part, one describes an original methodology to optimize the process and geometry parameters in injection stage based on the combination of design of experiments and an adaptive Response Surface Modeling. Then the second part of the paper describes the identification strategy that one proposes for the sintering stage, using the identification of sintering parameters from dilatometeric curves followed by the optimization of the sintering process. The proposed approaches are applied to the optimization of material and process parameters for manufacturing a ceramic femoral implant. One demonstrates that the proposed approach give satisfactory results.
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Desai, Parind M; Hogan, Rachael C; Brancazio, David; Puri, Vibha; Jensen, Keith D; Chun, Jung-Hoon; Myerson, Allan S; Trout, Bernhardt L
2017-10-05
This study provides a framework for robust tablet development using an integrated hot-melt extrusion-injection molding (IM) continuous manufacturing platform. Griseofulvin, maltodextrin, xylitol and lactose were employed as drug, carrier, plasticizer and reinforcing agent respectively. A pre-blended drug-excipient mixture was fed from a loss-in-weight feeder to a twin-screw extruder. The extrudate was subsequently injected directly into the integrated IM unit and molded into tablets. Tablets were stored in different storage conditions up to 20 weeks to monitor physical stability and were evaluated by polarized light microscopy, DSC, SEM, XRD and dissolution analysis. Optimized injection pressure provided robust tablet formulations. Tablets manufactured at low and high injection pressures exhibited the flaws of sink marks and flashing respectively. Higher solidification temperature during IM process reduced the thermal induced residual stress and prevented chipping and cracking issues. Polarized light microscopy revealed a homogeneous dispersion of crystalline griseofulvin in an amorphous matrix. DSC underpinned the effect of high tablet residual moisture on maltodextrin-xylitol phase separation that resulted in dimensional instability. Tablets with low residual moisture demonstrated long term dimensional stability. This study serves as a model for IM tablet formulations for mechanistic understanding of critical process parameters and formulation attributes required for optimal product performance. Copyright © 2017 Elsevier B.V. All rights reserved.
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Transferability of glass lens molding
NASA Astrophysics Data System (ADS)
Katsuki, Masahide
2006-02-01
Sphere lenses have been used for long time. But it is well known that sphere lenses theoretically have spherical aberration, coma and so on. And, aspheric lenses attract attention recently. Plastic lenses are molded easily with injection machines, and are relatively low cost. They are suitable for mass production. On the other hand, glass lenses have several excellent features such as high refractive index, heat resistance and so on. Many aspheric glass lenses came to be used for the latest digital camera and mobile phone camera module. It is very difficult to produce aspheric glass lenses by conventional process of curve generating and polishing. For the solution of this problem, Glass Molding Machine was developed and is spreading through the market. High precision mold is necessary to mold glass lenses with Glass Molding Machine. The mold core is ground or turned by high precision NC aspheric generator. To obtain higher transferability of the mold core, the function of the molding machine and the conditions of molding are very important. But because of high molding temperature, there are factors of thermal expansion and contraction of the mold and glass material. And it is hard to avoid the factors. In this session, I introduce following items. [1] Technology of glass molding and the machine is introduced. [2] The transferability of glass molding is analyzed with some data of glass lenses molded. [3] Compensation of molding shape error is discussed with examples.
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DOE Office of Scientific and Technical Information (OSTI.GOV)
Nguyen, Ba Nghiep; Kunc, Vlastimil; Jin, Xiaoshi
2013-12-18
This article illustrates the predictive capabilities for long-fiber thermoplastic (LFT) composites that first simulate the injection molding of LFT structures by Autodesk® Simulation Moldflow® Insight (ASMI) to accurately predict fiber orientation and length distributions in these structures. After validating fiber orientation and length predictions against the experimental data, the predicted results are used by ASMI to compute distributions of elastic properties in the molded structures. In addition, local stress-strain responses and damage accumulation under tensile loading are predicted by an elastic-plastic damage model of EMTA-NLA, a nonlinear analysis tool implemented in ABAQUS® via user-subroutines using an incremental Eshelby-Mori-Tanaka approach. Predictedmore » stress-strain responses up to failure and damage accumulations are compared to the experimental results to validate the model.« less
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A study on the development of engineering plastic piston used in the shock absorber
NASA Astrophysics Data System (ADS)
Kim, Young-Ho; Bae, Won-Byong; Lim, Dong-Ju; Suh, Yun-Soo
1998-08-01
A piston is an important component of the shock absorber which determines comfortable riding and handling. Conventional piston is made of metal powder that is pressed in a mold, and then sintered at high temperatures below the melting point before machining processes such as drilling, sizing and teflon banding. This study aims at cutting down cost and weight, and improving the process by replacing the traditional sintering process used for manufacturing the shock absorber with the injection molding process adopting engineering plastics as raw material. To analyze the injection molding process, we used the commercial program, MOLDFLOW, and obtained an optimal combination of the process parameters. In addition, by comparing the engineering plastic piston with the metal powder piston through the formability and the performance experiments, we confirmed the availability of this alternative process suggested.
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Rheological study of copper and copper grapheme feedstock for powder injection molding
NASA Astrophysics Data System (ADS)
Azaman, N. Emira Binti; Rafi Raza, M.; Muhamad, N.; Niaz Akhtar, M.; Bakar Sulong, A.
2017-01-01
Heatsink is one of the solution to optimize the performance of smart electronic devices. Copper and its composites are helping the electronic industry to solve the heating problem. Copper-graphene heat sink material with enhanced thermal conductivity is the ultimate goal.Powder injection molding (PIM) has advantages of high precision and production rate, complex shape, low cost and suitabality for metal and cremics.PIM consists of four sub sequential steps; feedstock preparation, molding, debinding and sintering. Feedstock preparation is a critical step in PIM process. Any deficiency at this stage cannot be recovered at latter stages. Therefore, this research was carried out to investigate the injectability of copper and copper graphene composite using PIM. PEG based multicomponent binder system was used and the powder loading was upto 7vol.% less than the critical powder loading was used to provide the wettability of the copper powder and graphene nanoplatelets (GNps). Corpper-graphene feedstock contained 0.5vol.% of GNps . To ensure the homogeneity of GNps within feedstock a unique technique was addopted. The microscopic results showed that the feedstock is homogeneous and ready for injection. The viscosity-shear rate relationship was determined and results showed that the addition of 0.5vol.% of GNps in copper has increased the viscosity upto 64.9% at 140˚C than that of pure copper feedstock. This attribute may be due to the large surface area of GNps. On the other hand, by increasing the temperature, viscosity of the feedstock was decreased, which was recommended for PIM. The overall viscosity and share rate lies within the range recommended for PIM process. It is clear that both feedstocks showed pseudo plastic behaviour which is suitable for PIM process. In the pseudo plastic behaviour, the viscosity decreases with the shear rate. It may be due to change in the structure of the solid particles or the binder. The molding results showed that both copper feedstocks were successfully molded and free from the physical defects.
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Takahashi, Yutaka; Hamanaka, Ippei; Shimizu, Hiroshi
2012-07-01
This study investigated the effect of thermal shock on the mechanical properties of injection-molded thermoplastic denture base resins. Four thermoplastic resins (two polyamides, one polyethylene terephthalate, one polycarbonate) and, as a control, a conventional heat-polymerized polymethyl methacrylate (PMMA), were tested. Specimens of each denture base material were fabricated according to ISO 1567 and were either thermocycled or not thermocycled (n = 10). The flexural strength at the proportional limit (FS-PL), the elastic modulus and the Charpy impact strength of the denture base materials were estimated. Thermocycling significantly decreased the FS-PL of one of the polyamides and the PMMA and it significantly increased the FS-PL of one of the polyamides. In addition, thermocycling significantly decreased the elastic modulus of one of the polyamides and significantly increased the elastic moduli of one of the polyamides, the polyethylene terephthalate, polycarbonate and PMMA. Thermocycling significantly decreased the impact strength of one of the polyamides and the polycarbonate. The mechanical properties of injection-molded thermoplastic denture base resins changed after themocycling.
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Magnesium Powder Injection Molding (MIM) of Orthopedic Implants for Biomedical Applications
NASA Astrophysics Data System (ADS)
Wolff, M.; Schaper, J. G.; Suckert, M. R.; Dahms, M.; Ebel, T.; Willumeit-Römer, R.; Klassen, T.
2016-04-01
Metal injection molding (MIM) has a high potential for the economic near-net-shape mass production of small-sized and complex-shaped parts. The motivation for launching Mg into the MIM processing chain for manufacturing biodegradable medical implants is related to its compatibility with human bone and its degradation in a non-toxic matter. It has been recognized that the load-bearing capacity of MIM Mg parts is superior to that of biodegradable polymeric components. However, the choice of appropriate polymeric binder components and alloying elements enabling defect-free injection molding and sintering is a major challenge for the use of MIM Mg parts. This study considered the full processing chain for MIM of Mg-Ca alloys to achieve ultimate tensile strength of up to 141 MPa with tensile yield strength of 73 MPa, elongation at fracture Af of 7% and a Young's modulus of 38 GPa. To achieve these mechanical properties, a thermal debinding study was performed to determine optimal furnace and atmosphere conditions, sintering temperature, heating rates, sintering time and pressure.
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Exploratory development of foams from liquid crystal polymers
NASA Technical Reports Server (NTRS)
Chung, T. S.
1985-01-01
Two types of liquid crystal polymer (LCP) compositions were studied and evaluated as structural foam materials. One is a copolymer of 6-hydroxy-2-naphthoic acid, terephthalic acid, and p-acetoxyacetanilide (designed HNA/TA/AAA), and the other is a copolymer of p-hydroxybenzoic acid and 6-hydroxy-2-naphthoic acid (designated HBA/HNA). Experimental results showed that the extruded HNA/TA/AA foams have better mechanical quality and appearance than HBA/HNA foams. Heat treatment improved foam tensile strength and break elongation, but reduced their modulus. The injection molding results indicated that nitrogen foaming agents with a low-pressure process gave better void distribution in the injection molded LCP foams than those made by the conventional injection-molding machine and chemical blowing agents. However, in comparing LCP foams with other conventional plastic foams, HBA/HNA foams have better mechanical properties than foamed ABS and PS, but are comparable to PBT and inferior to polycarbonate foams, especially in heat-deflection temperature and impact resistance energy. These deficiencies are due to LCP molecules not having been fully oriented during the Union-Carbide low-pressure foaming process.
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Mold Heating and Cooling Pump Package Operator Interface Controls Upgrade
DOE Office of Scientific and Technical Information (OSTI.GOV)
Josh A. Salmond
2009-08-07
The modernization of the Mold Heating and Cooling Pump Package Operator Interface (MHC PP OI) consisted of upgrading the antiquated single board computer with a proprietary operating system to off-the-shelf hardware and off-the-shelf software with customizable software options. The pump package is the machine interface between a central heating and cooling system that pumps heat transfer fluid through an injection or compression mold base on a local plastic molding machine. The operator interface provides the intelligent means of controlling this pumping process. Strict temperature control of a mold allows the production of high quality parts with tight tolerances and lowmore » residual stresses. The products fabricated are used on multiple programs.« less
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Gazzaniga, Andrea; Cerea, Matteo; Cozzi, Alberto; Foppoli, Anastasia; Maroni, Alessandra; Zema, Lucia
2011-03-01
The feasibility of injection molding was explored in the preparation of a novel capsular device for oral pulsatile/delayed delivery based on swellable/erodible polymers. For this purpose, a mold intended to be coupled with a bench-top injection-molding press was designed. This was expected to enable the preparation of matching capsule cap and body items within a single manufacturing cycle and the selection of differing shell thicknesses (300, 600, and 900 μm). Hydroxypropylcellulose (Klucel(®) EF, LF, and GF) was employed as the release-controlling polymer in admixture with polyethylene glycol 1500 (10%, w/w) as the plasticizer. After preliminary trials aimed at the setup of operating conditions, Klucel(®) EF and LF capsule shells with satisfactory technological properties were manufactured. The performance of capsular devices filled with a tracer drug powder was studied by means of a modified USP31 disintegration apparatus. Typical in vitro delayed release patterns were thereby obtained, with lag time increasing as a function of the wall thickness. A good correlation was found between the latter parameter and t (10%), i.e., the time to 10% release, for both polymer grades employed. On the basis of the overall results, the investigated technique was proven suitable for the manufacturing of an innovative pulsatile release platform. © 2011 American Association of Pharmaceutical Scientists
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Low-Cost Production of Composite Bushings for Jet Engine Applications
NASA Technical Reports Server (NTRS)
Gray, Robert A.
1998-01-01
The objectives of this research program were to reduce the manufacturing costs of variable stator vane bushings by 1) eliminating the expensive carbon fiber braiding operation, 2) replacing the batch mode impregnation, B-stage, and cutting operations with a continuous process, and 3) reducing the molding cycle and machining operations with injection molding to achieve near-net shapes. Braided bushings were successfully fabricated with both AMB-17XLD and AMB-TPD resin systems. The composite bushings achieved high glass transition temperature after post-cure (+300 C) and comparable weight loss to the PNM-15 bushings. ANM-17XLD bushings made with "batch-mode" molding compound (at 0.5 in. fiber length) achieved a +300 lb-force flange break strength which was superior to the continuous braided-fiber reinforced bushing. The non-MDA resin technology developed in this contract appears attractive for bushing applications that do not exceed a 300 C use temperature. Two thermoplastic polyimide resins were synthesized in order to generate injection molding compound powders. Excellent processing results were obtained at injection temperatures in excess of 300 C. Micro-tensile specimens were produced from each resin type and the Tg measurements (by TMA) for these samples were equivalent to AURUM(R). Thermal Gravimetric Analysis (TGA) conducted at 10 C/min showed that the non-MDA AMB-type polyimide thermoplastics had comparable weight loss to PMR-15 up to 500 C.
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NASA Astrophysics Data System (ADS)
Nguyen Thi, T. B.; Yokoyama, A.; Ota, K.; Kodama, K.; Yamashita, K.; Isogai, Y.; Furuichi, K.; Nonomura, C.
2014-05-01
One of the most important challenges in the injection molding process of the short-glass fiber/thermoplastic composite parts is being able to predict the fiber orientation, since it controls the mechanical and the physical properties of the final parts. Folgar and Tucker included into the Jeffery equation a diffusive type of term, which introduces a phenomenological coefficient for modeling the randomizing effect of the mechanical interactions between the fibers, to predict the fiber orientation in concentrated suspensions. Their experiments indicated that this coefficient depends on the fiber volume fraction and aspect ratio. However, a definition of the fiber interaction coefficient, which is very necessary in the fiber orientation simulations, hasn't still been proven yet. Consequently, this study proposed a developed fiber interaction model that has been introduced a fiber dynamics simulation in order to obtain a global fiber interaction coefficient. This supposed that the coefficient is a sum function of the fiber concentration, aspect ratio, and angular velocity. The proposed model was incorporated into a computer aided engineering simulation package C-Mold. Short-glass fiber/polyamide-6 composites were produced in the injection molding with the fiber weight concentration of 30 wt.%, 50 wt.%, and 70 wt.%. The physical properties of these composites were examined, and their fiber orientation distributions were measured by micro-computed-tomography equipment μ-CT. The simulation results showed a good agreement with experiment results.
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Fabrication of Composite Material Using Gettou Fiber by Injection Molding
NASA Astrophysics Data System (ADS)
Setsuda, Roy; Fukumoto, Isao; Kanda, Yasuyuki
This study investigated the mechanical properties of composite using gettou (shell ginger) fiber as reinforcement fabricated from injection molding. Gettou fiber is a natural fiber made from gettou, a subtropical plant that is largely abundant in Okinawa, Japan. We used the stem part of gettou plant and made the gettou fiber by crushing the stem. The composite using gettou fiber contributed to low shrinkage ratio, high bending strength and high flexural modulus. The mechanical strength of composite using long gettou fiber showed higher value than composite using short gettou fiber. Next, because gettou is particularly known for its anti-mold characteristic, we investigated the characteristic in gettou plastic composite. The composite was tested against two molds: aspergillius niger and penicillium funiculosum. The 60% gettou fiber plastic composite was found to satisfy the JISZ2801 criterion. Finally, in order to predict the flexural modulus of composite using gettou fiber by Halpin-Tsai equation, the tensile elastic modulus of single gettou fiber was measured. The tendency of the experimental results of composite using gettou fiber was in good agreement with Halpin-Tsai equation.
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Dang, Fuquan; Tabata, Osamu; Kurokawa, Masaya; Ewis, Ashraf A; Zhang, Lihua; Yamaoka, Yoshihisa; Shinohara, Shouji; Shinohara, Yasuo; Ishikawa, Mitsuru; Baba, Yoshinobu
2005-04-01
We have developed a novel technique for mass production of microfabricated capillary array electrophoresis (mu-CAE) plastic chips for high-speed, high-throughput genetic analysis. The mu-CAE chips, containing 10 individual separation channels of 50-microm width, 50-microm depth, and a 100-microm lane-to-lane spacing at the detection region and a sacrificial channel network, were fabricated on a poly(methyl methacrylate) substrate by injection molding and then bonded manually using a pressure-sensitive sealing tape within several seconds at room temperature. The conditions for injection molding and bonding were carefully characterized to yield mu-CAE chips with well-defined channel and injection structures. A CCD camera equipped with an image intensifier was used to monitor simultaneously the separation in a 10-channel array with laser-induced fluorescence detection. High-performance electrophoretic separations of phiX174 HaeIII DNA restriction fragments and PCR products related to the human beta-globin gene and SP-B gene (the surfactant protein B) have been demonstrated on mu-CAE plastic chips using a methylcellulose sieving matrix in individual channels. The current work demonstrated greatly simplified the fabrication process as well as a detection scheme for mu-CAE chips and will bring the low-cost mass production and application of mu-CAE plastic chips for genetic analysis.
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Compact surface plasmon resonance biosensor utilizing an injection-molded prism
NASA Astrophysics Data System (ADS)
Chen, How-Foo; Chen, Chih-Han; Chang, Yun-Hsiang; Chuang, Hsin-Yuan
2016-05-01
Targeting at a low cost and accessible diagnostic device in clinical practice, a compact surface plasmon resonance (SPR) biosensor with a large dynamic range in high sensitivity is designed to satisfy commercial needs in food safety, environmental bio-pollution monitoring, and fast clinical diagnosis. The core component integrates an optical coupler, a sample-loading plate, and angle-tuning reflectors is injection-molded as a free-from prism made of plastic optics. This design makes a matching-oil-free operation during operation. The disposability of this low-cost component ensures testing or diagnosis without cross contamination in bio-samples.
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Mechanical recycling of continuous fiber-reinforced thermoplastic sheets
NASA Astrophysics Data System (ADS)
Moritzer, Elmar; Heiderich, Gilmar
2016-03-01
This contribution examines possible material recycling of offcuts generated during the production of continuous-fiber-reinforced composite sheets. These sheets consist of a polyamide 6 matrix and glass fiber fabric. In the initial step, the offcut is shredded to obtain particles; following that, the particles are processed in a twin-screw process to produce fiber-reinforced plastic pellets with varying fiber contents. These pellets are intended for use in injection molding processes as a substitution for new raw materials. This investigation centers on the mechanical properties which can be achieved with the recycled material after both the twin-screw process and injection molding.
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NASA Technical Reports Server (NTRS)
Whalen, Thomas J.; Baer, J. R.
1989-01-01
The influence on density and strength of pressureless sintering in vacuum and argon environments has been evaluated with injection molded SiC materials. Main effects and two factor interactions of sintering (cycle variables temperature, time, heating rate, and atmosphere) were assessed. An improved understanding of the influence of the processing flaws and sintering conditions has been obtained. Strength and density have improved from a baseline level of 299 MPa (43.3 Ksi) and 94 pct of theoretical density to values greater than 483 MPa (70 Ksi) and 97 pct.
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NASA Technical Reports Server (NTRS)
Cooper, K. G.
2000-01-01
Rapid prototyping (RP) is a layer-by-layer-based additive manufacturing process for constructing three-dimensional representations of a computer design from a wax, plastic, or similar material. Wire arc spray (WAS) is a metal spray forming technique, which deposits thin layers of metal onto a substrate or pattern. Marshall Space Flight Center currently has both capabilities in-house, and this project proposed merging the two processes into an innovative manufacturing technique, in which intermediate injection molding tool halves were to be fabricated with RP and WAS metal forming.
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Zhao, Dapeng; Chang, Keke; Ebel, Thomas; Qian, Ma; Willumeit, Regine; Yan, Ming; Pyczak, Florian
2013-12-01
The application of titanium (Ti) based biomedical materials which are widely used at present, such as commercially pure titanium (CP-Ti) and Ti-6Al-4V, are limited by the mismatch of Young's modulus between the implant and the bones, the high costs of products, and the difficulty of producing complex shapes of materials by conventional methods. Niobium (Nb) is a non-toxic element with strong β stabilizing effect in Ti alloys, which makes Ti-Nb based alloys attractive for implant application. Metal injection molding (MIM) is a cost-efficient near-net shape process. Thus, it attracts growing interest for the processing of Ti and Ti alloys as biomaterial. In this investigation, metal injection molding was applied to the fabrication of a series of Ti-Nb binary alloys with niobium content ranging from 10wt% to 22wt%, and CP-Ti for comparison. Specimens were characterized by melt extraction, optical microscopy, X-ray diffraction (XRD), scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), and transmission electron microscopy (TEM). Titanium carbide formation was observed in all the as-sintered Ti-Nb binary alloys but not in the as-sintered CP-Ti. Selected area electron diffraction (SAED) patterns revealed that the carbides are Ti2C. It was found that with increasing niobium content from 0% to 22%, the porosity increased from about 1.6% to 5.8%, and the carbide area fraction increased from 0% to about 1.8% in the as-sintered samples. The effects of niobium content, porosity and titanium carbides on mechanical properties have been discussed. The as-sintered Ti-Nb specimens exhibited an excellent combination of high tensile strength and low Young's modulus, but relatively low ductility. © 2013 Elsevier Ltd. All rights reserved.
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Injection molding of high precision optics for LED applications made of liquid silicone rubber
DOE Office of Scientific and Technical Information (OSTI.GOV)
Hopmann, Christian; Röbig, Malte
Light Emitting Diodes (LED) conquer the growing global market of lighting technologies. Due to their advantages, they are increasingly used in consumer products, in lighting applications in the home and in the mobility sector as well as in industrial applications. Particularly, with regard to the increasing use of high-power LED (HP-LED) the materials in the surrounding area of the light emitting semiconductor chip are of utmost importance. While the materials behind the semiconductor chip are optimized for maximum heat dissipation, the materials currently used for the encapsulation of the semiconductor chip (primary optics) and the secondary optics encounter their limitsmore » due to the high temperatures. In addition certain amounts of blue UV radiation degrade the currently used materials such as epoxy resins or polyurethanes for primary optics. In the context of an ongoing joint research project with various partners from the industry, an innovative manufacturing method for high precision optics for LED applications made of liquid silicone rubber (LSR) is analyzed at the Institut of Plastics Processing (IKV), Aachen. The aim of this project is to utilize the material-specific advantages of high transparent LSR, especially the excellent high temperature resistance and the great freedom in design. Therefore, a high integrated injection molding process is developed. For the production of combined LED primary and secondary optics a LED board is placed in an injection mold and overmolded with LSR. Due to the integrated process and the reduction of subcomponents like the secondary optics the economics of the production process can be improved significantly. Furthermore combined LED optics offer an improved effectiveness, because there are no losses of the light power at the transition of the primary and secondary optics.« less
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Flow monitoring of microwave pre-heated resin in LCM processes
NASA Astrophysics Data System (ADS)
Rubino, F.; Paradiso, V.; Carlone, P.
2017-10-01
Liquid composite molding is manufacturing techniques that involve the injection or infusion of catalyzed liquid resin into a mold to impregnate a dry fiber preform. The challenges of LCM processes are related to the obtaining of a complete wetting of the reinforcement as well as a reduction of the void to obtain a final product with high mechanical properties. The heating of the resin prior the injection into the mold cavity has proven to be useful to improve the LCM processes. The increasing of temperature results in a reduction of resin viscosity and allows the resin to flow more easily through the reinforcement; the cure stage is also improved resulting in a reduction of global process time required. Besides the conventional solutions to heat up the resin based on the thermal conduction, in-line microwave heating is a suitable method to heat dielectric materials providing an even temperature distribution through the resin, thereby avoiding a thermal gradient between the surface and the core of liquid resin, which could result in a premature and uncontrolled cure. In the present work, an in-line microwave system, manually controlled, have been coupled with a VARTM apparatus to heat the resin before the infusion. In addition, parallel-plate dielectric sensors and pressure sensors, embedded into the mold, were employed to track the flow front through the fiber reinforcement in two distinct cases: unheated resin and pre-heated resin. The aim of work was to assess the effectiveness of microwave pre-heating to improve the macro and micro-impregnation of dry preform. The obtained results showed capability of in-line microwave heating to shorten the impregnation of dry fabric and provide a homogeneous wetting of fibers.
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Investigation of sample preparation on the moldability of ceramic injection molding feedstocks
NASA Astrophysics Data System (ADS)
Ide, Jared
Ceramic injection molding is a desirable option for those who are looking to make ceramic parts with complex geometries. Formulating the feedstock needed to produce ideal parts is a difficult process. In this research a series of feedstock blends will be evaluated for moldability. This was done by investigating their viscosity, and how certain components affect the overall ability to flow. These feedstocks varied waxes, surfactants, and solids loading. A capillary rheometer was used to characterize some of the materials, which led to one batch being selected for molding trials. The parts were sintered and further refinements were made to the feedstock. Solids loading was increased from 77.5% to 82%, which required different ratios of organics to flow. Finally, the ceramic powders were treated to lower their specific surface area before being compounded, which resulted in materials that would process easily through an extruder and exhibit properties suitable for CIM.
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Kim, Hong-Kyun; Woo, Kyung mi; Shon, Won-Jun; Ahn, Jin-Soo; Cha, Seunghee; Park, Young-Seok
2017-01-01
The aim of this study was to compare osseointegration and surface characteristics of zirconia implants made by the powder injection molding (PIM) technique and made by the conventional milling procedure in rabbit tibiae. Surface characteristics of 2 types of implant were evaluated. Sixteeen rabbits received 2 types of external hex implants with similar geometry, machined zirconia implants and PIM zirconia implants, in the tibiae. Removal torque tests and histomorphometric analyses were performed. The roughness of PIM zirconia implants was higher than that of machined zirconia implants. The PIM zirconia implants exhibited significantly higher bone-implant contact and removal torque values than the machined zirconia implants (P < 0.001). The osseointegration of the PIM zirconia implant is promising, and PIM, using the roughened mold etching technique, can produce substantially rough surfaces on zirconia implants. PMID:26235717
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A versatile approach to vacuum injection casting for materials research and development.
Xu, Donghua; Xu, Yifan
2017-03-01
Vacuum injection casting (VIC) is important for research and development (R&D) of materials that are prone to oxidation at high temperatures, particularly metals and metallic alloys (e.g., metallic glasses and high entropy alloys). VIC in R&D laboratories often involves initial melting/alloying in a prior step, transporting the sample to a dedicated vacuum chamber, re-melting the sample in a quartz tube, and finally injecting the melt with an inert gas to a dedicated mold. Here we present a new approach to laboratory VIC that requires no sample transfer (for a variety of materials), no dedicated vacuum chamber/space nor dedicated mold, and hence provides more versatility and higher efficiency and yet lowers the capital equipment cost. Our approach takes advantage of the exceptional portability, thermal and chemical stability, and thermoplastic processability of quartz glass and uses quartz tubes for all the melting, re-melting, injection casting, and molding. In addition, our approach includes oxygen gettering to remove residual oxygen for all the steps and allows for slow or fast cooling (e.g., water quenching) upon injection. This paper focuses on the design, the procedures, and the versatile features of this new approach while also demonstrating the practical implementation of this approach and computational modeling of the heat transfer and the cooling rates for two exemplary cases. The new approach is expected to bring notable expedition to sample fabrication and materials discovery, as well as wider adoption of vacuum injection casting in materials science and condensed matter physics research laboratories.
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A versatile approach to vacuum injection casting for materials research and development
NASA Astrophysics Data System (ADS)
Xu, Donghua; Xu, Yifan
2017-03-01
Vacuum injection casting (VIC) is important for research and development (R&D) of materials that are prone to oxidation at high temperatures, particularly metals and metallic alloys (e.g., metallic glasses and high entropy alloys). VIC in R&D laboratories often involves initial melting/alloying in a prior step, transporting the sample to a dedicated vacuum chamber, re-melting the sample in a quartz tube, and finally injecting the melt with an inert gas to a dedicated mold. Here we present a new approach to laboratory VIC that requires no sample transfer (for a variety of materials), no dedicated vacuum chamber/space nor dedicated mold, and hence provides more versatility and higher efficiency and yet lowers the capital equipment cost. Our approach takes advantage of the exceptional portability, thermal and chemical stability, and thermoplastic processability of quartz glass and uses quartz tubes for all the melting, re-melting, injection casting, and molding. In addition, our approach includes oxygen gettering to remove residual oxygen for all the steps and allows for slow or fast cooling (e.g., water quenching) upon injection. This paper focuses on the design, the procedures, and the versatile features of this new approach while also demonstrating the practical implementation of this approach and computational modeling of the heat transfer and the cooling rates for two exemplary cases. The new approach is expected to bring notable expedition to sample fabrication and materials discovery, as well as wider adoption of vacuum injection casting in materials science and condensed matter physics research laboratories.
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Carey, Robert I; Kyle, Christopher C; Carey, Donna L; Leveillee, Raymond J
2008-01-01
To prepare artificial kidney stones of defined shape, size, mass, and material composition via precision injection molding of Ultracal 30 cement slurries into an inexpensive biodegradable mold. A calcium alginate and silica-based mold was used to prepare casts of varying shapes in a reproducible manner. Ultracal 30 cement slurries mixed 1:1 with water were injected into these casts and allowed to harden. The artificial stones were recovered and their physical properties determined. Ex-vivo and in-vivo responses to holmium laser lithotripsy were examined. Spheres, half spheres, cylinders, cubes, tapered conical structures, and flat angulated structures were prepared with high precision without post-molding manipulations. Large spheres of average mass 0.661 g (+/- 0.037), small spheres of average mass 0.046 g (+/- 0.0026), and hexagons of average mass 0.752 g (+/- 0.0180) were found to have densities (1610-1687 kg/m(3)) within the expected range for Ultracal 30 cement stones. Ex-vivo holmium laser lithotripsy of small spheres in saline showed uniformly reproducible efficiencies of comminution. Implantation of a tapered conical stone into the ureter of a porcine model demonstrated stone comminution in vivo consistent with that seen in the ex-vivo models. We present an environmentally safe, technically simple procedure for the formation of artificial kidney stones of predetermined size and shape. The technique does not require the use of hazardous solvents or postprocedural processing of the stones. These stones are intended for use in standardized experiments of lithotripsy efficiency in which the shape of the stone as well as the mass can be predetermined and precisely controlled.
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INTEGRATION OF COST MODELS AND PROCESS SIMULATION TOOLS FOR OPTIMUM COMPOSITE MANUFACTURING PROCESS
DOE Office of Scientific and Technical Information (OSTI.GOV)
Pack, Seongchan; Wilson, Daniel; Aitharaju, Venkat
Manufacturing cost of resin transfer molded composite parts is significantly influenced by the cycle time, which is strongly related to the time for both filling and curing of the resin in the mold. The time for filling can be optimized by various injection strategies, and by suitably reducing the length of the resin flow distance during the injection. The curing time can be reduced by the usage of faster curing resins, but it requires a high pressure injection equipment, which is capital intensive. Predictive manufacturing simulation tools that are being developed recently for composite materials are able to provide variousmore » scenarios of processing conditions virtually well in advance of manufacturing the parts. In the present study, we integrate the cost models with process simulation tools to study the influence of various parameters such as injection strategies, injection pressure, compression control to minimize high pressure injection, resin curing rate, and demold time on the manufacturing cost as affected by the annual part volume. A representative automotive component was selected for the study and the results are presented in this paper« less
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Nayak, Rabindra S; Shafiuddin, Bareera; Pasha, Azam; Vinay, K; Narayan, Anjali; Shetty, Smitha V
2015-07-01
Technological advances in wire selection and bracket design have led to improved treatment efficiency and allowed longer time intervals between appliance adjustments. The wires remain in the mouth for a longer duration and are subjected to electrochemical reactions, mechanical forces of mastication and generalized wear. These cause different types of corrosion. This study was done to compare the galvanic currents generated between different combinations of brackets and archwires commonly used in orthodontic practices. The materials used for the study included different commercially available orthodontic archwires and brackets. The galvanic current generated by individual materials and different combinations of these materials was tested and compared. The orthodontic archwires used were 0.019″ × 0.025″ heat-activated nickel-titanium (3M Unitek), 0.019″ × 0.025″ beta-titanium (3M Unitek) and 0.019″ × 0.025″ stainless steel (3M Unitek). The orthodontic brackets used were 0.022″ MBT laser-cut (Victory Series, 3M Unitek) and metal-injection molded (Leone Company) maxillary central incisor brackets respectively. The ligature wire used for ligation was 0.009″ stainless steel ligature (HP Company). The galvanic current for individual archwires, brackets, and the different bracket-archwire-ligature combinations was measured by using a Potentiostat machine. The data were generated using the Linear Sweep Voltammetry and OriginPro 8.5 Graphing and Data Analysis Softwares. The study was conducted in two phases. Phase I comprised of five groups for open circuit potential (OCP) and galvanic current (I), whereas Phase II comprised of six groups for galvanic current alone. Mean, standard deviation and range were computed for the OCP and galvanic current (I) values obtained. Results were subjected to statistical analysis through ANOVA. In Phase I, higher mean OCP was recorded in stainless steel archwire, followed by beta-titanium archwire, heat-activated nickel titanium archwire, laser-cut bracket and metal-injection molded bracket, respectively. The difference in mean OCP recorded among the groups was found to be statistically significant in aerated phosphate buffered saline solution. The galvanic current (I) for metal-injection molded stainless steel brackets showed significantly higher values than all the other materials. Phase II results suggested that, in the couples formed by the archwire-bracket-ligature combinations, the bracket had more important contribution to the total galvanic current generated, since there were significant differences between galvanic current among the 2 brackets tested but not among the 3 wires. The galvanic current of the metal-injection molded bracket was significantly higher than that of laser-cut bracket. Highest mean current (I) was recorded in metal-injection molded bracket when used with heat-activated nickel titanium archwire while lowest mean current (I) was recorded in laser-cut bracket when used with beta-titanium archwire. The present study concluded that the bracket emerged to be the most important factor in determining the galvanic current (I). Higher mean current (I) was recorded in metal-injection molded bracket compared to laser-cut bracket. Among the three archwires, higher mean current (I) was recorded in heat-activated nickel-titanium, followed by stainless-steel and beta-titanium respectively. When coupled together; highest mean current (I) was recorded in metal-injection molded bracket when used with heat-activated nickel titanium archwire while lowest mean current (I) was recorded in laser-cut bracket when used with beta-titanium archwire.
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Wavefront measurement of plastic lenses for mobile-phone applications
NASA Astrophysics Data System (ADS)
Huang, Li-Ting; Cheng, Yuan-Chieh; Wang, Chung-Yen; Wang, Pei-Jen
2016-08-01
In camera lenses for mobile-phone applications, all lens elements have been designed with aspheric surfaces because of the requirements in minimal total track length of the lenses. Due to the diffraction-limited optics design with precision assembly procedures, element inspection and lens performance measurement have become cumbersome in the production of mobile-phone cameras. Recently, wavefront measurements based on Shack-Hartmann sensors have been successfully implemented on injection-molded plastic lens with aspheric surfaces. However, the applications of wavefront measurement on small-sized plastic lenses have yet to be studied both theoretically and experimentally. In this paper, both an in-house-built and a commercial wavefront measurement system configured on two optics structures have been investigated with measurement of wavefront aberrations on two lens elements from a mobile-phone camera. First, the wet-cell method has been employed for verifications of aberrations due to residual birefringence in an injection-molded lens. Then, two lens elements of a mobile-phone camera with large positive and negative power have been measured with aberrations expressed in Zernike polynomial to illustrate the effectiveness in wavefront measurement for troubleshooting defects in optical performance.
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Chemorheology of in-mold coating for compression molded SMC applications
NASA Astrophysics Data System (ADS)
Ko, Seunghyun; Straus, Elliott J.; Castro, Jose M.
2015-05-01
In-mold coating (IMC) is applied to compression molded sheet molding compound (SMC) exterior automotive or truck body panels as an environmentally friendly alternative to make the surface conductive for subsequent electrostatic painting operations. The coating is a thermosetting liquid that when injected onto the surface of the part cures and bonds to provide a smooth conductive surface. In order to optimize the IMC process, it is essential to predict the time available for flow, that is the time before the thermosetting reaction starts (inhibition time) as well as the time when the coating has enough structural integrity so that the mold can be opened without damaging the part surface (cure time). To predict both the inhibition time and the cure time, it is critical to study the chemorheology of IMC. In this paper, we study the chemorheology for a typical commercial IMC system, and show its relevance to both the flow and cure time for the IMC stage during SMC compression molding.
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Linear and volumetric dimensional changes of injection-molded PMMA denture base resins.
El Bahra, Shadi; Ludwig, Klaus; Samran, Abdulaziz; Freitag-Wolf, Sandra; Kern, Matthias
2013-11-01
The aim of this study was to evaluate the linear and volumetric dimensional changes of six denture base resins processed by their corresponding injection-molding systems at 3 time intervals of water storage. Two heat-curing (SR Ivocap Hi Impact and Lucitone 199) and four auto-curing (IvoBase Hybrid, IvoBase Hi Impact, PalaXpress, and Futura Gen) acrylic resins were used with their specific injection-molding technique to fabricate 6 specimens of each material. Linear and volumetric dimensional changes were determined by means of a digital caliper and an electronic hydrostatic balance, respectively, after water storage of 1, 30, or 90 days. Means and standard deviations of linear and volumetric dimensional changes were calculated in percentage (%). Statistical analysis was done using Student's and Welch's t tests with Bonferroni-Holm correction for multiple comparisons (α=0.05). Statistically significant differences in linear dimensional changes between resins were demonstrated at all three time intervals of water immersion (p≤0.05), with exception of the following comparisons which showed no significant difference: IvoBase Hi Impact/SR Ivocap Hi Impact and PalaXpress/Lucitone 199 after 1 day, Futura Gen/PalaXpress and PalaXpress/Lucitone 199 after 30 days, and IvoBase Hybrid/IvoBase Hi Impact after 90 days. Also, statistically significant differences in volumetric dimensional changes between resins were found at all three time intervals of water immersion (p≤0.05), with exception of the comparison between PalaXpress and Futura Gen. Denture base resins (IvoBase Hybrid and IvoBase Hi Impact) processed by the new injection-molding system (IvoBase), revealed superior dimensional precision. Copyright © 2013 Academy of Dental Materials. Published by Elsevier Ltd. All rights reserved.
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Heidari, Behzad Shiroud; Davachi, Seyed Mohammad; Moghaddam, Amin Hedayati; Seyfi, Javad; Hejazi, Iman; Sahraeian, Razi; Rashedi, Hamid
2018-05-01
In this study, injection molding process of ultrahigh molecular weight polyethylene (UHMWPE) reinforced with nano-hydroxyapatite (nHA) was simulated and optimized through minimizing the shrinkage and warpage of the hip liners as an essential part of a hip prosthesis. Fractional factorial design (FFD) was applied to the design of the experiment, modeling, and optimizing the shrinkage and warpage of UHMWPE/nHA composite liners. The Analysis of variance (ANOVA) was applied to find the importance of operative parameters and their effects. In this experiment, seven input parameters were surveyed, including mold temperature (A), melt temperature (B), injection time (C), packing time (D), packing pressure (E), coolant temperature (F), and type of liner (G). Two models were capable of predicting warpage and volumetric shrinkage (%) in different conditions with R 2 of 0.9949 and 0.9989, respectively. According to the models, the optimized values of warpage and volumetric shrinkage are 0.287222 mm and 13.6613%, respectively. Meanwhile, a finite element analysis (FE analysis) was also carried out to examine the stress distribution in liners under the force values of demanding and daily activities. The Von-Mises stress distribution showed that both of the liners can be applied to all activities with no failure. However, UHMWPE/nHA liner is more resistant to the highest loads than UHMWPE liner due to the effect of nHA in the nanocomposite. Finally, according to the results of injection molding simulations, optimization, structural analysis as well as the tensile strength and wear resistance, UHMWPE/nHA liner is recommended for the production of a hip prosthesis. Copyright © 2018 Elsevier Ltd. All rights reserved.
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Yu, Feilong; Deng, Hua; Bai, Hongwei; Zhang, Qin; Wang, Ke; Chen, Feng; Fu, Qiang
2015-05-20
Various methods have been devoted to trigger the formation of multilayered structure for wide range of applications. These methods are often complicated with low production efficiency or require complex equipment. Herein, we demonstrate a simple and efficient method for the fabrication of polymeric sheets containing multilayered structure with enhanced barrier property through high speed thin-wall injection molding (HSIM). To achieve this, montmorillonite (MMT) is added into PE first, then blended with PP to fabricate PE-MMT/PP ternary composites. It is demonstrated that alternating multilayer structure could be obtained in the ternary composites because of low interfacial tension and good viscosity match between different polymer components. MMT is selectively dispersed in PE phase with partial exfoliated/partial intercalated microstructure. 2D-WAXD analysis indicates that the clay tactoids in PE-MMT/PP exhibits an uniplanar-axial orientation with their surface parallel to the molded part surface, while the tactoids in binary PE-MMT composites with the same overall MMT contents illustrate less orientation. The enhanced orientation of nanoclay in PE-MMT/PP could be attributed to the confinement of alternating multilayer structure, which prohibits the tumbling and rotation of nanoplatelets. Therefore, the oxygen barrier property of PE-MMT/PP is superior to that of PE-MMT because of increased gas permeation pathway. Comparing with the results obtained for PE based composites in literature, outstanding barrier property performance (45.7% and 58.2% improvement with 1.5 and 2.5 wt % MMT content, respectively) is achieved in current study. Two issues are considered responsible for such improvement: enhanced MMT orientation caused by the confinement in layered structure, and higher local density of MMT in layered structure induced denser assembly. Finally, enhancement in barrier property by confining impermeable filler into alternating multilayer structure through such simple and efficient method could provide a novel route toward high-performance packaging materials and other functional materials require layered structure.
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NASA Technical Reports Server (NTRS)
Waterman, A. W.; Huxford, R. L.; Nelson, W. G.
1976-01-01
Molded high temperature plastic first and second stage rod seal elements were evaluated in seal assemblies to determine performance characteristics. These characteristics were compared with the performance of machined seal elements. The 6.35 cm second stage Chevron seal assembly was tested using molded Chevrons fabricated from five molding materials. Impulse screening tests conducted over a range of 311 K to 478 K revealed thermal setting deficiencies in the aromatic polyimide molding materials. Seal elements fabricated from aromatic copolyester materials structurally failed during impulse cycle calibration. Endurance testing of 3.85 million cycles at 450 K using MIL-H-83283 fluid showed poorer seal performance with the unfilled aromatic polyimide material than had been attained with seals machined from Vespel SP-21 material. The 6.35 cm first stage step-cut compression loaded seal ring fabricated from copolyester injection molding material failed structurally during impulse cycle calibration. Molding of complex shape rod seals was shown to be a potentially controllable technique, but additional molding material property testing is recommended.
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Fatigue-propagation du melange polymere polystyrene/polyethylene
NASA Astrophysics Data System (ADS)
Bureau, Martin N.
The interrelations between the morphology of PS/HDPE and PS/SEBS/HDPE immiscible polymer blends and their mechanical behavior, namely in monotonic loading and in cyclic loading, were studied. As predicted by theory, high shear rates encountered during extrusion blending led to efficient minor phase emulsification in PS/HDPE blends for which the viscosity ratio approaches unity. Consequently, the emulsifying effect of an SEBS triblock copolymer employed as a compatibilizer was found to be negligible. In subsequent molding process, disintegration, shape relaxation and coarsening of the minor phase domains were responsible for the morphological evolution of the blends. In the compression molding process, morphological observations showed that the rate of minor phase coarsening followed the predictions of the Ostwald ripening theory, in agreement with the rheological analysis. In the injection molding process, minor phase coarsening was attributed to shear coalescence. The fatigue crack propagation behavior of injection-molded specimens of pure PS as well as of 95/5, 85/15 and 70/30 PS/HDPE blends and of 95/(0.5/4.5), 85/(1.5/13.5) and 70/(3/27) PS/(SEBS/HDPE) blends was then studied. The fatigue fracture surface features of specimens of pure PS as well as of PS/HDPE and PS/SEBS/HDPE blends were analyzed in detail in order to interpret their fatigue crack propagation behavior. In pure PS specimens, discontinuous growth bands, associated with the fracture of crazes in the plastic zone, formed at low fatigue crack growth rates, large dimple-like features at intermediate fatigue crack growth rates and fatigue striations at high fatigue crack growth rates. The fracture toughness of injection-molded specimens of pure PS as well as of 95/5, 85/15 and 70/30 PS/HDPE blends and of 95/(0.5/4.5) PS/(SEBS/HDPE), 85/(1.5/13.5) and 70/(3/27) PS/(SEBS/HDPE) was finally studied. The results showed that the addition of HDPE to PS led to a reduction of the fracture toughness KQ following ASTM E-399 when compared to that of pure PS. This effect was attributed to the very fine minor phase morphology of the blends obtained after extrusion blending and injection molding. (Abstract shortened by UMI.)
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Using magnetic levitation for non-destructive quality control of plastic parts.
Hennek, Jonathan W; Nemiroski, Alex; Subramaniam, Anand Bala; Bwambok, David K; Yang, Dian; Harburg, Daniel V; Tricard, Simon; Ellerbee, Audrey K; Whitesides, George M
2015-03-04
Magnetic levitation (MagLev) enables rapid and non-destructive quality control of plastic parts. The feasibility of MagLev as a method to: i) rapidly assess injection-molded plastic parts for defects during process optimization, ii) monitor the degradation of plastics after exposure to harsh environmental conditions, and iii) detect counterfeit polymers by density is demonstrated. © 2015 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.
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DOE Office of Scientific and Technical Information (OSTI.GOV)
Nguyen, Ba Nghiep; Bapanapalli, Satish K.; Smith, Mark T.
2008-09-01
The objective of our work is to enable the optimum design of lightweight automotive structural components using injection-molded long fiber thermoplastics (LFTs). To this end, an integrated approach that links process modeling to structural analysis with experimental microstructural characterization and validation is developed. First, process models for LFTs are developed and implemented into processing codes (e.g. ORIENT, Moldflow) to predict the microstructure of the as-formed composite (i.e. fiber length and orientation distributions). In parallel, characterization and testing methods are developed to obtain necessary microstructural data to validate process modeling predictions. Second, the predicted LFT composite microstructure is imported into amore » structural finite element analysis by ABAQUS to determine the response of the as-formed composite to given boundary conditions. At this stage, constitutive models accounting for the composite microstructure are developed to predict various types of behaviors (i.e. thermoelastic, viscoelastic, elastic-plastic, damage, fatigue, and impact) of LFTs. Experimental methods are also developed to determine material parameters and to validate constitutive models. Such a process-linked-structural modeling approach allows an LFT composite structure to be designed with confidence through numerical simulations. Some recent results of our collaborative research will be illustrated to show the usefulness and applications of this integrated approach.« less
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DOE Office of Scientific and Technical Information (OSTI.GOV)
Nguyen Thi, T. B., E-mail: thanhbinh.skku@gmail.com, E-mail: yokoyama@kit.ac.jp; Yokoyama, A., E-mail: thanhbinh.skku@gmail.com, E-mail: yokoyama@kit.ac.jp; Ota, K., E-mail: kei-ota@toyobo.jp, E-mail: katsuhiro-kodama@toyobo.jp, E-mail: katsuhisa-yamashita@toyobo.jp, E-mail: yumiko-isogai@toyobo.jp, E-mail: kenji-furuichi@toyobo.jp, E-mail: chisato-nonomura@toyobo.jp
2014-05-15
One of the most important challenges in the injection molding process of the short-glass fiber/thermoplastic composite parts is being able to predict the fiber orientation, since it controls the mechanical and the physical properties of the final parts. Folgar and Tucker included into the Jeffery equation a diffusive type of term, which introduces a phenomenological coefficient for modeling the randomizing effect of the mechanical interactions between the fibers, to predict the fiber orientation in concentrated suspensions. Their experiments indicated that this coefficient depends on the fiber volume fraction and aspect ratio. However, a definition of the fiber interaction coefficient, whichmore » is very necessary in the fiber orientation simulations, hasn't still been proven yet. Consequently, this study proposed a developed fiber interaction model that has been introduced a fiber dynamics simulation in order to obtain a global fiber interaction coefficient. This supposed that the coefficient is a sum function of the fiber concentration, aspect ratio, and angular velocity. The proposed model was incorporated into a computer aided engineering simulation package C-Mold. Short-glass fiber/polyamide-6 composites were produced in the injection molding with the fiber weight concentration of 30 wt.%, 50 wt.%, and 70 wt.%. The physical properties of these composites were examined, and their fiber orientation distributions were measured by micro-computed-tomography equipment μ-CT. The simulation results showed a good agreement with experiment results.« less
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Metal injection molding of titanium for medical and aerospace applications
NASA Astrophysics Data System (ADS)
Scharvogel, Matthias; Winkelmueller, Wendelin
2011-02-01
Mixing of titanium powder and thermoplastic binders creates a feedstock that is injection molded similar to plastic, has a chemical and thermal debinding process, and then is sintered to form a net-shape or near-net shape part. TiJet Medizintechnik GmbH (TiJet) developed and uses its own feedstock and powder processing technology to achieve desired mechanical properties. This paper explains the theory of the process and the possibilities that result from the development of this new powder processing technology, such as new alloys, design possibilities, etc. Discussed will be the microstructure, chemical composition, and mechanical properties of the manufactured parts.
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NASA Astrophysics Data System (ADS)
Baltes, Henry; Brand, Oliver; Fedder, Gary K.; Hierold, Christofer; Korvink, Jan G.; Tabata, Osamu; Löhe, Detlef; Haußelt, Jürgen
2005-09-01
Microstructures, electronics, nanotechnology - these vast fields of research are growing together as the size gap narrows and many different materials are combined. Current research, engineering sucesses and newly commercialized products hint at the immense innovative potentials and future applications that open up once mankind controls shape and function from the atomic level right up to the visible world without any gaps. In this volume, authors from three major competence centres for microengineering illustrate step by step the process from designing and simulating microcomponents of metallic and ceramic materials to replicating micro-scale components by injection molding.
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Carlson, Kristen; Chidley, Matthew; Sung, Kung-Bin; Descour, Michael; Gillenwater, Ann; Follen, Michele; Richards-Kortum, Rebecca
2005-04-01
For in vivo optical diagnostic technologies to be distributed to the developed and developing worlds, optical imaging systems must be constructed of inexpensive components. We present a fiber-optic confocal reflectance microscope with a cost-effective injection-molded plastic miniature objective lens for in vivo imaging of human tissues in near real time. The measured lateral resolution is less than 2.2 microm, and the measured axial resolution is 10 microm. Confocal images of ex vivo cervical tissue biopsies and in vivo human lip taken at 15 frames/s demonstrate the microscope's capability of imaging cell morphology and tissue architecture.
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Recent progress in online ultrasonic process monitoring
NASA Astrophysics Data System (ADS)
Wen, Szu-Sheng L.; Chen, Tzu-Fang; Ramos-Franca, Demartonne; Nguyen, Ky T.; Jen, Cheng-Kuei; Ihara, Ikuo; Derdouri, A.; Garcia-Rejon, Andres
1998-03-01
On-line ultrasonic monitoring of polymer co-extrusion and gas-assisted injection molding are presented. During the co- extrusion of high density polyethylene and Santoprene ultrasonic sensors consisting of piezoelectric transducers and clad ultrasonic buffer rods are used to detect the interface between these two polymers and the stability of the extrusion. The same ultrasonic sensor also measures the surface temperature of the extruded polymer. The results indicate that temperature measurements using ultrasound have a faster response time than those obtained by conventional thermocouple. In gas-assisted injection molding the polymer and gas flow front positions are monitored simultaneously. This information may be used to control the plunger movement.
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The technology and commercial status of powder-injection molding
NASA Astrophysics Data System (ADS)
Bose, Animesh
1995-08-01
The process of powder-injection molding (PIM) is a viable and competitive commercial technique that is being used to process complex-shaped parts of various materials in moderate to high volumes. The hey advantage of the process is its unique ability to combine materials selection flexibility with the complex shape-forming ability of plastics. Although the PIM process has been discussed in the open literature for more than quarter of a century, it has become a commercial reality only during the last decade or so. Currently, there is a tremendous interest in this unique technology throughout the world. As a result, the PIM industry is poised for significant growth.
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NASA Astrophysics Data System (ADS)
Rahim, Tuan Noraihan Azila Tuan; Abdullah, Abdul Manaf; Akil, Hazizan Md; Mohamad, Dasmawati
2016-12-01
The emergence of 3D printing technology known as fused filament fabrication (FFF) has offered the possibility of producing an anatomically accurate, patient specific implant with more affordable prices. The only weakness of this technology is related to incompatibility and lack of properties of current material to be applied in biomedical. Therefore, this study aims to develop a new, polymer composite-based biomaterial that exhibits a high processability using FFF technique, strong enough and shows acceptable biocompatibility, and safe for biomedical use. Polyamide 12 (PA12), which meets all these requirements was incorporated with two bioceramic fillers, zirconia and hydroxyapatite in order to improve the mechanical and bioactivity properties. The obtained mechanical properties were compared with injection-molded specimens and also a commercial biomedical product, HAPEXTM which is composed of hydroxyapatite and polyethylene. The yield strength and modulus of the PA12 composites increased steadily with increasing filler loading. Although the strength of printed PA12 composites were reduced compared with injection molded specimen, but still higher than HAPEXTM material. The higher surface roughness obtained by printed PA12 was expected to enhance the cell adhesion and provide better implant fixation.
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Desai, Parind M; Puri, Vibha; Brancazio, David; Halkude, Bhakti S; Hartman, Jeremy E; Wahane, Aniket V; Martinez, Alexander R; Jensen, Keith D; Harinath, Eranda; Braatz, Richard D; Chun, Jung-Hoon; Trout, Bernhardt L
2018-01-01
We developed and evaluated a solvent-free injection molding (IM) coating technology that could be suitable for continuous manufacturing via incorporation with IM tableting. Coating formulations (coating polymers and plasticizers) were prepared using hot-melt extrusion and screened via stress-strain analysis employing a universal testing machine. Selected coating formulations were studied for their melt flow characteristics. Tablets were coated using a vertical injection molding unit. Process parameters like softening temperature, injection pressure, and cooling temperature played a very important role in IM coating processing. IM coating employing polyethylene oxide (PEO) based formulations required sufficient room humidity (>30% RH) to avoid immediate cracks, whereas other formulations were insensitive to the room humidity. Tested formulations based on Eudrajit E PO and Kollicoat IR had unsuitable mechanical properties. Three coating formulations based on hydroxypropyl pea starch, PEO 1,000,000 and Opadry had favorable mechanical (<700MPa Young's modulus, >35% elongation, >95×10 4 J/m 3 toughness) and melt flow (>0.4g/min) characteristics, that rendered acceptable IM coats. These three formulations increased the dissolution time by 10, 15 and 35min, respectively (75% drug release), compared to the uncoated tablets (15min). Coated tablets stored in several environmental conditions remained stable to cracking for the evaluated 8-week time period. Copyright © 2017 Elsevier B.V. All rights reserved.
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Development of piezoelectric composites for transducers
NASA Astrophysics Data System (ADS)
Safari, A.
1994-07-01
For the past decade and a half, many different types of piezoelectric ceramic-polymer composites have been developed intended for transducer applications. These diphasic composites are prepared from non-active polymer, such as epoxy, and piezoelectric ceramic, such as PZT, in the form of filler powders, elongated fibers, multilayer and more complex three-dimensional structures. For the last four years, most of the efforts have been given to producing large area and fine scale PZT fiber composites. In this paper, processing of piezoelectric ceramic-polymer composites with various connectivity patterns are reviewed. Development of fine scale piezoelectric composites by lost mold, injection molding and the relic method are described. Research activities of different groups for preparing large area piezocomposites for hydrophone and actuator applications are briefly reviewed. Initial development of electrostrictive ceramics and composites are also
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Huang, Yan-Fei; Xu, Jia-Zhuang; Li, Jian-Shu; He, Ben-Xiang; Xu, Ling; Li, Zhong-Ming
2014-08-01
The low efficiency of fabrication of ultrahigh molecular weight polyethylene (UHMWPE)-based artificial knee joint implants is a bottleneck problem because of its extremely high melt viscosity. We prepared melt processable UHMWPE (MP-UHMWPE) by addition of 9.8 wt% ultralow molecular weight polyethylene (ULMWPE) as a flow accelerator. More importantly, an intense shear flow was applied during injection molding of MP-UHMWPE, which on one hand, promoted the self-diffusion of UHMWPE chains, thus effectively reducing the structural defects; on the other hand, increased the overall crystallinity and induced the formation of self-reinforcing superstructure, i.e., interlocked shish-kebabs and oriented lamellae. Aside from the good biocompatibility, and the superior fatigue and wear resistance to the compression-molded UHMWPE, the injection-molded MP-UHMWPE exhibits a noteworthy enhancement in tensile properties and impact strength, where the yield strength increases to 46.3 ± 4.4 MPa with an increment of 128.0%, the ultimate tensile strength and Young's modulus rise remarkably up to 65.5 ± 5.0 MPa and 1248.7 ± 45.3 MPa, respectively, and the impact strength reaches 90.6 kJ/m(2). These results suggested such melt processed and self-reinforced UHMWPE parts hold a great application promise for use of knee joint implants, particularly for younger and more active patients. Our work sets up a new method to fabricate high-performance UHMWPE implants by tailoring the superstructure during thermoplastic processing. Copyright © 2014 Elsevier Ltd. All rights reserved.
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Processing-microstructure models for short- and long-fiber thermoplastic composites
NASA Astrophysics Data System (ADS)
Phelps, Jay H.
The research for this thesis has explored the important microstructural variables for injection-molded thermoplastic composites with discontinuous fiber reinforcement. Two variables, the distributions of fiber orientation and fiber length after processing, have proven to be not only important for correct material property prediction but also difficult to predict using currently available modeling and simulation techniques. In this work, we develop new models for the prediction of these two microstructural variables. Previously, the Folgar-Tucker model has been widely used to predict fiber orientation in injection molded SFT composites. This model accounts for the effects of both hydrodynamics and fiber-fiber interactions in order to give a prediction for a tensorial measure of fiber orientation. However, when applied to at least some classes of LFTs, this model does not match all components of experimental fiber orientation tensor data. In order to address this shortcoming of the model, we hypothesize that Folgar and Tucker's phenomenological treatment of the effects of fiber-fiber interactions with an isotropic rotary diffusion contribution to the rate of change of orientation is insufficient for materials with longer fibers. Instead, this work develops a fiber orientation model that incorporates anisotropic rotary diffusion (ARD). From kinetic theory we derive a general family of evolution equations for the second-order orientation tensor, correcting errors in earlier treatments, and identify a specific equation that is useful for predicting orientation in LFTs. The amount of diffusivity in this model used to approximate the effect of fiber-fiber interactions in each direction is assumed to depend on a second-order space tensor, which is taken to be a function of the orientation state and the rate of deformation. Also, concentrated fiber suspensions align more slowly with respect to strain than the Folgar-Tucker model predicts. Here, we borrow the technique of Wang et al. (2008) to incorporate this behavior in an objective fashion in this new model. Model parameters are selected by matching the experimental steady-state orientation in simple shear flow, and by requiring stable steady states and physically realizable solutions. Utilizing two separate techniques, we identify model parameters for three different materials. We then show that once a set of parameters that meets all previously established criteria has been identified, the differences in model behavior are negligible within that set of parameters. The final model with the proper parameter set is suitable for use in mold filling and other flow simulations, and does give improved predictions of fiber orientation for injection molded LFTs. Although significant fiber length degradation in LFTs has been observed both in literature and in this work, there are no quantitative fiber breakage models to predict either fiber length distributions or average fiber length measures. This work reviews the suspected causes of fiber breakage during the processing of discontinuously-reinforced thermoplastics, specifically LFTs, and introduces a phenomenological fiber breakage model based on the buckling force in a hydrodynamically loaded fiber. This breakage model is incorporated into a conservation equation for total fiber length, and a phenomenological model for the evolution of the fiber length distribution is developed. From this model, we also develop separate, approximate models for the evolution of both the number-average and weight-average fiber length measures. By applying these models to both a simple numerical example and a more complex mold-filling simulation, a qualitative agreement between experiment and prediction is observed. Although these results are promising, the breakage models have only been applied to the mold cavity in injection molding simulation. Both a literature review and our experimental data strongly suggest that the majority of fiber length degradation occurs in the earlier stages of injection molding, in the screw nozzle, runners, and gate. A better understanding of the melting and flow conditions upstream of the mold cavity, the simulation of which is beyond the scope of this work, is needed before these breakage models can be properly applied to the entire injection molding process. (Abstract shortened by UMI.)
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DOE Office of Scientific and Technical Information (OSTI.GOV)
2009-10-14
EMTA-NLA is a computer program for analyzing the nonlinear stiffness, strength, and thermo-elastic properties of discontinuous fiber composite materials. Discontinuous fiber composites are chopped-fiber reinforced polymer materials that are formed by injection molding or compression molding techniques. The fibers tend to align during forming as the composite flows and fills the mold. EMTA-NLA can read the fiber orientation data from the molding software, Autodesk Moldflow Plastics Insight, and calculate the local material properties for accurately analyzing the warpage, stiffness, and strength of the as-formed composite part using the commercial NLA software. Therefore, EMTA-NLA is a unique assembly of mathematical algorithmsmore » that provide a one-of-a-kind composites constitutive model that links these two powerful commercial software packages.« less
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On the use of topology optimization for improving heat transfer in molding process
NASA Astrophysics Data System (ADS)
Agazzi, A.; LeGoff, R.; Truc-Vu, C.
2016-10-01
In the plastic industry, one of the key factor is to control heat transfer. One way to achieve that goal is to design an effective cooling system. But in some area of the mold, where it is not possible to design cooling system, the use of a highly conductive material, such as copper pin, is often used. Most of the time, the location, the size and the quantity of the copper pin are made by empirical considerations, without using optimization procedures. In this article, it is proposed to use topology optimization, in order to improve transient conductive heat transfer in an injection/blowing mold. Two methodologies are applied and compared. Finally, the optimal distribution of cooper pin in the mold is given.
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DOE Office of Scientific and Technical Information (OSTI.GOV)
Li, Ling; Post, Brian; Kunc, Vlastimil
Additive manufacturing (AM) or 3D printing is well known for producing arbitrary shaped parts without any tooling required, offering a promising alternative to the conventional injection molding method to fabricate near-net-shaped magnets. In order to determine their applicability in the fabrication of Nd-Fe-B bondedmagnets, we compare two 3D printing technologies, namely binder jetting and material extrusion. Some prospects and challenges of these state-of-the-art technologies for large-scale industrial applications will be discussed.
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JPRS Report, Science & Technology Europe
1992-08-12
Head on Chip Industry, Plans [Heinrich von Pierer Interview; Bonn DIE WELT, 15 Jun 92] 33 Swiss Contraves Develops High-Density Multichip Module... Investment costs are low because the method is based on low pressure, 0.1-1.0 MPA, during injection. This permits the use of simpler molds and...For example, ABS Pumpen AG [ABS Pumps German Stock Corporation] in Lohmar needed 1.5 years to define the "Ceramic Compo- nents for Friction
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DOE Office of Scientific and Technical Information (OSTI.GOV)
Nguyen, Ba Nghiep; Fifield, Leonard S.; Wollan, Eric J.
2015-11-13
During the last quarter of FY 2015, the following technical progress has been made toward project milestones: 1) PlastiComp used the PlastiComp direct in-line (D-LFT) Pushtrusion system to injection mold 40 30wt% LCF/PP parts with ribs, 40 30wt% LCF/PP parts without ribs, 10 30wt% LCF/PA66 parts with ribs, and 35 30wt% LCF/PA66 parts without ribs. In addition, purge materials from the injection molding nozzle were obtained for fiber length analysis, and molding parameters were sent to PNNL for process modeling. 2) Magna cut samples at four selected locations (named A, B, C and D) from the non-ribbed Magna-molded parts basedmore » on a plan discussed with PNNL and the team and shipped these samples to Virginia Tech for fiber orientation and length measurements. 3) Virginia Tech started fiber orientation and length measurements for the samples taken from the complex parts using Virginia Tech’s established procedure. 4) PNNL and Autodesk built ASMI models for the complex parts with and without ribs, reviewed process datasheets and performed preliminary analyses of these complex parts using the actual molding parameters received from Magna and PlastiComp to compare predicted to experimental mold filling patterns. 5) Autodesk assisted PNNL in developing the workflow to use Moldflow fiber orientation and length results in ABAQUS® simulations. 6) Autodesk advised the team on the practicality and difficulty of material viscosity characterization from the D-LFT process. 7) PNNL developed a procedure to import fiber orientation and length results from a 3D ASMI analysis to a 3D ABAQUS® model for structural analyses of the complex part for later weight reduction study. 8) In discussion with PNNL and Magna, Toyota developed mechanical test setups and built fixtures for three-point bending and torsion tests of the complex parts. 9) Toyota built a finite element model for the complex parts subjected to torsion loading. 10) PNNL built the 3D ABAQUS® model of the complex ribbed part subjected to 3-point bending. 11) University of Illinois (Prof. C.L. Tucker) advised the team on fiber orientation and fiber length measurement options, modeling issues as well as interpretation of data.« less
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Applications of thin carbon coatings and films in injection molding
NASA Astrophysics Data System (ADS)
Cabrera, Eusebio Duarte
In this research, the technical feasibility of two novel applications of thin carbon coatings is demonstrated. The first application consists of using thin carbon coatings on molds for molding ultra-thin plastic parts (<0.5 mm thickness) with lower pressures by promoting wall slip. The second application consists of a new approach to provide electromagnetic interference (EMI) shielding for plastic parts using in mold coated nanoparticle thin films or nanopapers to create a conductive top layer. During this research, the technical feasibility of a new approach was proven which provides injection molding of ultra-thin parts at lower pressures, without the need of fast heating/fast cooling or other expensive mold modification. An in-house developed procedure by other members of our group, was employed for coating the mold surface using chemical vapor deposition (CVD) resulting in a graphene coating with carbide bonding to the mold surface. The coating resulted in a significant decrease of surface friction and consequently easiness of flow when compared to their uncoated counterparts. Thermoplastic polymers and their composites are a very attractive alternative but are hindered by the non-conductive nature of polymers. There are two general approaches used to date to achieve EMI shielding for plastic products. One is to spray a conductive metal coating onto the plastic surface forming a layer that must maintain its shielding effectiveness (SE), and its adhesion to the plastic throughout the expected life of the product. However, metal coatings add undesirable weight and tend to corrode over time. Furthermore, scratching the coating may create shielding failure; therefore, a protective topcoat may be required. The other approach is to use polymer composites filled with conductive fillers such as carbon black (CB), carbon nanofiber (CNF), and carbon nanotube (CNT). While conductive fillers may increase the electrical conductivity of polymer composites, the loading of such fillers often cannot reach a high level (<10 wt. %) due to the dispersion difficulty and exponential increase in viscosity. In this research, the technical feasibility of a new approach to EMI shielding of plastic parts was proven using in mold coated nanoparticle thin films or nanopapers to create a conductive top layer. For many years, in-mold coating (IMC) has been commercially applied to Sheet Molding Compound (SMC) compression molded parts, as an environmentally friendly approach to improve its surface quality and provide the required conductivity for electrostatic painting using carbon black (CB). Such process can also be applied to injection molding for creating a top conductive layer. Increasing the amount of CB will increase the surface conductivity of the coated part, thus improving the paint transfer efficiency. However the CB levels needed to achieve the conductivity levels required for achieving EMI shielding would make the coating viscosity too large for proper coating. Nanopaper based composites are excellent candidates for EMI shielding because of the nanopaper's high concentration of carbon nanofibers (CNFs) (~2 wt% to 10 wt% depending on nanopaper/thermoplastic thickness and 71wt.% to 79wt.% in the nanopaper itself after resin infusion) and high conductivity of the nanopaper. Instead of premixing nanoparticles with IMC coating, nanopapers enable the use of low viscosity IMC without CB coating to impregnate the CNF network in order to reach high electrical conductivity and EMI shielding values. (Abstract shortened by UMI.).
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ERIC Educational Resources Information Center
Society of the Plastics Industry, Inc., Washington, DC.
Designed to guide training and curriculum development to prepare machine operators for the national certification exam, this publication identifies the important knowledge required for productive performance by a plastics machine operator. Introductory material discusses the rationale for a national standard, uses of the Body of Knowledge,…
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JPRS Report. Science & Technology: Japan.
1988-12-09
Molding Technology [Takashi Kasai , Akihiko Hirota; KIKAI TO KOGU, May 88] 106 Injection Molding Technology [Toshiyuki Iwahashi; KIKAI TO KOGU, May 88...Development Shu Isa -Planning Office Fumio Sato —Control Office Shizuka Kudo - Patent Office Taro Inoue —Technical Information Office Takeshi...the possibility that a more serious situation could occur. Fumio Kaneko, who is in charge of the marine sector, joined the company in 1971 after
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Kramschuster, Adam; Turng, Lih-Sheng
2010-02-01
In this research, injection molding was combined with a novel material combination, supercritical fluid processing, and particulate leaching techniques to produce highly porous and interconnected structures that have the potential to act as scaffolds for tissue engineering applications. The foamed structures, molded with polylactide (PLA) and polyvinyl alcohol (PVOH) with salt as the particulate, were processed without the aid of organic solvents, which can be detrimental to tissue growth. The pore size in the scaffolds is controlled by salt particulates and interconnectivity is achieved by the co-continuous blending morphology of biodegradable PLA matrix with water-soluble PVOH. Carbon dioxide (CO(2)) at the supercritical state is used to serve as a plasticizer, thereby imparting moldability of blends even with an ultra high salt particulate content, and allows the use of low processing temperatures, which are desirable for temperature-sensitive biodegradable polymers. Interconnected pores of approximately 200 microm in diameter and porosities of approximately 75% are reported and discussed.
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Cellulose-reinforced composites and SRIM and RTM modeling
NASA Astrophysics Data System (ADS)
Fahrurrozi, Mohammad
Structural reaction injection molding (SRIM) cellulosic/polyurethane composites were prepared from various forms of cellulosic mats, and elastomeric polyurea-urethane (PUU) and rigid polyurethane (PU) formulations. Mats (woven and non-woven) prepared from different sources of fibers with lignin content ranging from zero (cotton) to at least 10% (sugar cane and kenaf fibers) performed comparably in PUU/cellulosic composites. Young's modulus and tensile strength of PUU/cellulosic composites were doubled with 5% and 7% fiber loading respectively. Young's modulus and tensile strength of PU/cellulosic composites were improved by 300% and 30%, respectively, with 7% fiber loading, whereas their bending moduli and strengths were improved up to 100% and 50%, respectively, with 18% fiber loading. However, the mechanical properties of PU composites were more sensitive to the fiber properties and fiber macroscopic arrangements. The study with chemical ratio variations indicates that as the fiber loading increases, the cellulose hydroxyl presence starts shifting the chemical balance and thus should be accounted for. Mats prepared from sugar cane fibers extracted from rind with low alkali concentration (0.2 N) followed by steam explosion require lower injection pressures compared to the ones prepared from fiber obtained from higher alkali treatment (above 0.5 N) without steam explosion. Hence, the steam exploded mats are more suitable for SRIM purposes. The PU kinetics was studied using an adiabatic temperature rise method. An Arrhenius type empirical equation was used to fit the data. The fitted equation was second order to the partial conversion, and the gelling time at adiabatic condition is less than 5 seconds (much quicker than the 10 to 12 seconds in mold gel time quoted by the manufacturer). FORTRAN programs were written to solve the SRIM model based on Darcy's equation. The model incorporated heat transfer and chemical reaction. The modeling was intended to aid in interpreting in-mold pressure data obtained from mat permeability characterization. The model also has other wider applications such as mold design and SRIM and resin transfer molding (RTM) simulation. The model predicts some experimental data from this work and the literature satisfactorily.
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NASA Astrophysics Data System (ADS)
Maruo, Shoji; Sugiyama, Kenji; Daicho, Yuya; Monri, Kensaku
2014-03-01
A three-dimensional (3-D) molding process using a master polymer mold produced by microstereolithography has been developed for the production of piezoelectric ceramic elements. In this method, ceramic slurry is injected into a 3-D polymer mold via a centrifugal casting process. The polymer master mold is thermally decomposed so that complex 3-D piezoelectric ceramic elements can be produced. As an example of 3-D piezoelectric ceramic elements, we produced a spiral piezoelectric element that can convert multidirectional loads into a voltage. It was confirmed that a prototype of the spiral piezoelectric element could generate a voltage by applying a load in both parallel and lateral directions in relation to the helical axis. The power output of 123 pW was obtained by applying the maximum load of 2.8N at 2 Hz along the helical axis. In addition, to improve the performance of power generation, we utilized a two-step sintering process to obtain dense piezoelectric elements. As a result, we obtained a sintering body with relative density of 92.8%. Piezoelectric constant d31 of the sintered body attained to -40.0 pC/N. Furthermore we analyzed the open-circuit voltage of the spiral piezoelectric element using COMSOL multiphysics. As a result, it was found that use of patterned electrodes according to the surface potential distribution of the spiral piezoelectric element had a potential to provide high output voltage that was 20 times larger than that of uniform electrodes.
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In-situ stabilization of radioactive zirconium swarf
Hess, Clay C.
1999-01-01
The method for treating ignitable cutting swarf in accordance with the present invention involves collecting cutting swarf in a casting mold underwater and injecting a binder mixture comprising vinyl ester styrene into the vessel to fill void volume; and form a mixture comprising swarf and vinyl ester styrene; and curing the mixture. The method is especially useful for stabilizing the ignitable characteristics of radioactive zirconium cutting swarf, and can be used to solidify zirconium swarf, or other ignitable finely divided material, underwater. The process could also be performed out of water with other particulate wastes.
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Forming of complex-shaped composite tubes using optimized bladder-assisted resin transfer molding
NASA Astrophysics Data System (ADS)
Schillfahrt, Christian; Fauster, Ewald; Schledjewski, Ralf
2018-05-01
This work addresses the manufacturing of tubular composite structures by means of bladder-assisted resin transfer molding using elastomeric bladders. In order to achieve successful processing of such parts, knowledge of the compaction and impregnation behavior of the textile preform is vital. Hence, efficient analytical models that describe the influencing parameters of the preform compaction and filling stage were developed and verified through practical experiments. A process window describing optimal and critical operating conditions during the injection stage was created by evaluating the impact of the relevant process pressures on filling time. Finally, a cascaded injection procedure was investigated that particularly facilitates the manufacturing of long composite tubes.
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Yu, X; Martin, S E; Schmidt, S J
2008-03-01
Mold growth is a common problem during the equilibration of food materials at high relative humidity values using the standard saturated salt slurry method. Exposing samples to toluene vapor and mixing samples with mold inhibitor chemicals are suggested methods for preventing mold growth while obtaining isotherms. However, no published research was found that examined the effect of mold growth on isotherm performance or the efficacy of various mold inhibitor methods, including their possible effect on the physicochemical properties of food materials. Therefore, the objectives of this study were to (1) explore the effect of mold growth on isotherm performance in a range of food materials, (2) investigate the effectiveness of 4 mold inhibitor methods, irradiation, 2 chemical inhibitors (potassium sorbate and sodium acetate), and toluene vapor, on mold growth on dent corn starch inoculated with A. niger, and (3) examine the effect of mold inhibitor methods on the physicochemical properties of dent corn starch, including isotherm performance, pasting properties, gelatinization temperature, and enthalpy. Mold growth was found to affect starch isotherm performance by contributing to weight changes during sample equilibration. Among the 4 mold inhibitor methods tested, irradiation and toluene vapor were found to be the most effective for inhibiting growth of A. niger on dent cornstarch. However, both methods exhibited a significant impact on the starches' physiochemical properties, suggesting the need to probe the efficacy of other mold inhibitor methods and explore the use of new rapid isotherm instruments, which hamper mold growth by significantly decreasing measurement time.
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Boonruksa, Pongsit; Bello, Dhimiter; Zhang, Jinde; Isaacs, Jacqueline A; Mead, Joey L; Woskie, Susan R
2017-07-01
In this study, the characteristics of airborne particles generated during injection molding and grinding processes of carbon nanotube reinforced polycarbonate composites (CNT-PC) were investigated. Particle number concentration, size distribution, and morphology of particles emitted from the processes were determined using real-time particle sizers and transmission electron microscopy. The air samples near the operator's breathing zone were collected on filters and analyzed using scanning electron microscope for particle morphology and respirable fiber count. Processing and grinding during recycling of CNT-PC released airborne nanoparticles (NPs) with a geometric mean (GM) particle concentration from 4.7 × 10 3 to 1.7 × 10 6 particles/cm 3 . The ratios of the GM particle concentration measured during the injection molding process with exhaust ventilation relative to background were up to 1.3 (loading), 1.9 (melting), and 1.4 (molding), and 101.4 for grinding process without exhaust ventilation, suggesting substantial NP exposures during these processes. The estimated mass concentration was in the range of 1.6-95.2 μg/m 3 . Diverse particle morphologies, including NPs, NP agglomerates, particles with embedded or protruding CNTs and fibers, were observed. No free CNTs were found during any of the investigated processes. The breathing zone respirable fiber concentration during the grinding process ranged from non-detectable to 0.13 fiber/cm 3 . No evidence was found that the emissions were affected by the number of recycling cycles. Institution of exposure controls is recommended during these processes to limit exposures to airborne NPs and CNT-containing fibers.
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Lobell, G.M.
1958-02-11
This patent is drawn to an injection molding apparatus for producing a tube closed at one end wherein the normally unsupported end of the core located in the cavity during the injection of the molten material to fill the space between the core and cavity wall, which supporting means is automatically removed from operation during the forming of the closed end of the tube. This support means is a plug extending through the end of the core into a recess in the bottom of the cavity where the closed end of the tube is to be formed. The plug is spring pressed into said recess and is forced out of the recess by a slidable bushing at the top of the cavity which is moved against the force of the spring by the molten material when it fills the uppormost open end portion of the cavity, thereby permitting the closed end of the tube to be formed.
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Baba, Masayuki; Matsumoto, Keitaro; Yamasaki, Naoya; Shindo, Hisakazu; Yano, Hiroshi; Matsumoto, Megumi; Otsubo, Ryota; John Lawn, Murray; Matsuo, Naoto; Yamamoto, Ikuo; Hidaka, Shigekazu; Nagayasu, Takeshi
Fine-needle aspiration cytology (FNAC) is a challenging and risky procedure for inexperienced clinicians to perform because of the proximity of the thyroid to the jugular veins, carotid arteries, and trachea. A phantom model for transfixion practice would help train clinicians in FNAC. To fabricate a tailored phantom with consideration for authenticity of size, touch, feel, and ultrasonographic (US) characteristics. A three-dimensional (3D) digital model of the human neck was reconstructed from computed tomography data of a subject. This model was used to create 3D-printed templates for various organs that require US visualization. The templates were injected with polymers that provided similar degrees of ultrasound permeability as the corresponding organs. For fabrication of each organ, the respective molds of organs, blood vessels, thyroid gland, and tumor were injected with the material. The fabricated components were then removed from the templates and colored. Individual components were then positioned in the neck mold, and agar gel was poured in. The complete phantom was then removed from the mold. Thereafter, 45 medical doctors and students performed ultrasound-guided FNAC using the phantom, following which they were queried regarding the value of the phantom. The structure, US characteristics, and elasticity of the phantom were similar to those of the human subject. In the survey, all 45 participants replied that they found the phantom useful for FNAC training, and 30 medical students professed increased interest in thyroid diseases after using the phantom. We successfully fabricated a tailored thyroid gland phantom for transfixion practice. As most of the phantom parts are injected in molds fabricated using a 3D printer, they can be easily reproduced once the molds are fabricated. This phantom is expected to serve as an effective and fully tailored training model for practicing thyroid gland transfixion. Copyright © 2017. Published by Elsevier Inc.
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Mass Manufacturing Challenges For CPV Primary And Secondary Optics
NASA Astrophysics Data System (ADS)
Luce, Thomas; Cohen, Joel
2010-10-01
Crucial for the performance and longevity of CPV installations is the efficiency of the optics used. Low production cost and high performance are key for the economical success of a CPV concept. To be able to compete with existing energy sources, proven mass production methods as well as high performance materials have to be employed. The injection molding process is the ideal serial production process capable to deliver at the same time high part quantities, excellent part precision and repeatable part quality at low manufacturing cost. Primary and secondary optics require different materials to be applied. The Pros and Cons of these materials in terms of production properties and achievable part precision will be discussed. We will show quality results for primary Fresnel optics using PMMA and, alternatively Silicone on Glass. For secondary optics we will demonstrate the use of optical silicone lenses widely used for high power LED applications today. Optical grade silicone has an excellent environmental stability even when encountering high energy density levels. The experience of Eschenbach Optik in injection molding silicone optics shows that this material is a very cost competitive alternative for glass secondary optics providing both highest optical performance and precision.
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Chidley, Matthew D; Carlson, Kristen D; Richards-Kortum, Rebecca R; Descour, Michael R
2006-04-10
The design, analysis, assembly methods, and optical-bench test results for a miniature injection-molded plastic objective lens used in a fiber-optic confocal reflectance microscope are presented. The five-lens plastic objective was tested as a stand-alone optical system before its integration into a confocal microscope for in vivo imaging of cells and tissue. Changing the spacing and rotation of the individual optical elements can compensate for fabrication inaccuracies and improve performance. The system performance of the miniature objective lens is measured by use of an industry-accepted slanted-edge modulation transfer function (MTF) metric. An estimated Strehl ratio of 0.61 and a MTF value of 0.66 at the fiber-optic bundle Nyquist frequency have been obtained. The optical bench testing system is configured to permit interactive optical alignment during testing to optimize performance. These results are part of an effort to demonstrate the manufacturability of low-cost, high-performance biomedical optics for high-resolution in vivo imaging. Disposable endoscopic microscope objectives could help in vivo confocal microscopy technology mature to permit wide-scale clinical screening and detection of early cancers and precancerous lesions.
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Bärwinkel, Stefanie; Seidel, Andreas; Hobeika, Sven; Hufen, Ralf; Mörl, Michaela; Altstädt, Volker
2016-01-01
Morphology formation during compounding, as well as injection molding of blends containing 60 wt % polycarbonate (PC) and 40 wt % polybutadiene rubber-modified styrene-acrylonitrile copolymers (ABS), has been investigated by transmission electron microscopy (TEM). Profiles of the blend morphology have been recorded in injection-molded specimens and significant morphology gradients observed between their skin and core. A <10 µm thick surface layer with strongly dispersed and elongated nano-scale (streak-like) styrene acrylonitrile (SAN) phases and well-dispersed, isolated SAN-grafted polybutadiene rubber particles is followed by a 50–150 µm thick skin layer in which polymer morphology is characterized by lamellar SAN/ABS phases. Thickness of these lamellae increases with the distance from the specimen’s surface. In the core of the specimens the SAN-grafted polybutadiene rubber particles are exclusively present within the SAN phases, which exhibit a much coarser and less oriented, dispersed morphology compared to the skin. The effects of the viscosity of the SAN in the PC/ABS blends on phase morphologies and correlations with fracture mechanics in tensile and impact tests were investigated, including scanning electron microscopy (SEM) assessment of the fracture surfaces. A model explaining the mechanisms of morphology formation during injection molding of PC/ABS blends is discussed. PMID:28773780
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NASA Astrophysics Data System (ADS)
Joo, Yeun-Ah; Kim, Young-Kyun; Yoon, Tae-Sik; Lee, Kee-Ahn
2018-03-01
This study investigated the microstructure and high temperature oxidation property of Fe-Cr-B metal/ceramic composite manufactured using powder injection molding process. Observations of initial microstructure showed a unique structure where α-Fe and (Cr, Fe)2B form a continuous three-dimensional network. High temperature oxidation tests were performed at 900, 1000 and 1100 °C, for 24 h, and the oxidation weight gain according to each temperature condition was 0.13, 0.84 and 6.4 mg/cm2, respectively. The oxidation results according to time at 900 and 1000 °C conditions represented parabolic curves, and at 1100 °C condition formed a rectilinear curve. Observation and phase analysis results of the oxides identified Cr2O3 and SiO2 at 900 and 1000 °C. In addition to Cr2O3 and SiO2, CrBO3 and FeCr2O4 formed due to phase decomposition of boride were identified at 1100 °C. Based on the findings above, this study suggested the high temperature oxidation mechanism of Fe-Cr-B metal/ceramic composite manufactured using powder injection molding, and the possibility of its application as a high temperature component material was also discussed.
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Vu, Lien T; Chen, Chao-Chang A; Yu, Chia-Wei
2018-02-05
This study aims to develop a new optical design method of soft multifocal contact lens (CLs) to obtain uniform optical power in large center-distance zone with optimized Non-Uniform Rational B-spline (NURBS). For the anterior surface profiles of CLs, the NURBS design curves are optimized to match given optical power distributions. Then, the NURBS in the center-distance zones are fitted in the corresponding spherical/aspheric curves for both data points and their centers of curvature to achieve the uniform power. Four cases of soft CLs have been manufactured by casting in shell molds by injection molding and then measured to verify the design specifications. Results of power profiles of these CLs are concord with the given clinical requirements of uniform powers in larger center-distance zone. The developed optical design method has been verified for multifocal CLs design and can be further applied for production of soft multifocal CLs.
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Flamant, Quentin; Caravaca, Carlos; Meille, Sylvain; Gremillard, Laurent; Chevalier, Jérôme; Biotteau-Deheuvels, Katia; Kuntz, Meinhard; Chandrawati, Rona; Herrmann, Inge K; Spicer, Christopher D; Stevens, Molly M; Anglada, Marc
2016-12-01
Due to their outstanding mechanical properties and excellent biocompatibility, zirconia-toughened alumina (ZTA) ceramics have become the gold standard in orthopedics for the fabrication of ceramic bearing components over the last decade. However, ZTA is bioinert, which hampers its implantation in direct contact with bone. Furthermore, periprosthetic joint infections are now the leading cause of failure for joint arthroplasty prostheses. To address both issues, an improved surface design is required: a controlled micro- and nano-roughness can promote osseointegration and limit bacterial adhesion whereas surface porosity allows loading and delivery of antibacterial compounds. In this work, we developed an integrated strategy aiming to provide both osseointegrative and antibacterial properties to ZTA surfaces. The micro-topography was controlled by injection molding. Meanwhile a novel process involving the selective dissolution of zirconia (selective etching) was used to produce nano-roughness and interconnected nanoporosity. Potential utilization of the porosity for loading and delivery of antibiotic molecules was demonstrated, and the impact of selective etching on mechanical properties and hydrothermal stability was shown to be limited. The combination of injection molding and selective etching thus appears promising for fabricating a new generation of ZTA components implantable in direct contact with bone. Zirconia-toughened alumina (ZTA) is the current gold standard for the fabrication of orthopedic ceramic components. In the present work, we propose an innovative strategy to provide both osseointegrative and antibacterial properties to ZTA surfaces: we demonstrate that injection molding allows a flexible design of surface micro-topography and can be combined with selective etching, a novel process that induces nano-roughness and surface interconnected porosity without the need for coating, avoiding reliability issues. These surface modifications have the potential to improve osseointegration. Furthermore, our results show that the porosity can be used for drug delivery and suggest that the etched surface could reduce bacterial adhesion. Copyright © 2016 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.
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Preparation and Characterization of PETI-330/Multiwalled Carbon Nanotube Composites
NASA Technical Reports Server (NTRS)
Ghose, Sayata; Watson, Kent A.; Working, Dennis C.; Delozier, Donavon M.; Criss, Jim M.; Siochi, Emilie J.; Connell, John W.
2005-01-01
As part of an ongoing effort to incorporate multi-functionality into advanced composites, blends of PETI-330 and multi-walled carbon nanotubes (MWCNTs) were prepared, characterized and fabricated into moldings. The PETI-330/MWCNT mixtures were prepared at concentrations ranging from 3 to 25 weight percent by dry mixing the components in a ball mill. The resulting powders were characterized for degree of mixing, thermal and rheological properties. Based on the characterization results, PETI-330/MWCNT samples were scaled up to approx. 300 g and used to fabricate moldings 10.2 cm x 15.2 cm x 0.32 cm thick. The moldings were fabricated by injecting the mixtures at 260-280 C into a stainless steel tool followed by curing for 1 h at 371 C. The tool was designed to impart high shear during the injection process in an attempt to achieve some alignment of the MWCNTs in the flow direction. Good quality moldings were obtained that were subsequently characterized for thermal, mechanical and electrical properties. The degree of dispersion and alignment of the MWCNTs were investigated using high-resolution scanning electron microscopy and Raman spectroscopy. The preparation and preliminary characterization of PETI-330/MWCNT composites will be discussed. Keywords: phenylethynyl terminated imides, high temperature polymers, nanocomposites,
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Gastroresistant capsular device prepared by injection molding.
Zema, Lucia; Loreti, Giulia; Melocchi, Alice; Maroni, Alessandra; Palugan, Luca; Gazzaniga, Andrea
2013-01-20
In the present work, the possibility of manufacturing by injection molding (IM) a gastro-resistant capsular device based on hydroxypropyl methyl cellulose acetate succinate (HPMCAS) was investigated. By performing as an enteric soluble container, such a device may provide a basis for the development of advantageous alternatives to coated dosage forms. Preliminarily, the processability of the selected thermoplastic polymer was evaluated, and the need for a plasticizer (polyethylene glycol 1500) in order to counterbalance the glassy nature of the molded items was assessed. However, some critical issues related to the physical/mechanical stability (shrinkage and warpage) and opening time of the device after the pH change were highlighted. Accordingly, an in-depth formulation study was carried out taking into account differing release modifiers potentially useful for enhancing the dissolution/disintegration rate of the capsular device at intestinal pH values. Capsule prototypes with thickness of 600 and 900 μm containing Kollicoat(®) IR and/or Explotab(®) CLV could be manufactured, and a promising performance was achieved with appropriate gastric resistance in pH 1.2 medium and break-up in pH 6.8 within 1h. These results would support the design of a dedicated mold for the development of a scalable manufacturing process. Copyright © 2012 Elsevier B.V. All rights reserved.
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Production of Insulated Footwear Using Liquid Injection Molding Equipment. 1. Method
1979-07-15
THE MACHINERY DR EQUIPMENT SPECIFIED 1A) WHEN IERMS AND CONDITIONS Of THE FACE AND REVERSE THIS CONFIRMATION IS SIGNED AND RETURNED By BUYER SIDES... BUYER ACCEPTS DELIVERY OF ALL OR ANY BUYER . SUPERSEDE OUYIER’S ORDER FORM IF ANY. AND PART aOF THE MACHINERY OR EQUIPMENT SPECIFIED CONSTITUTE THE...ENTIRE CONTRACT BETWEEN BUYER AFTER RECEIVING AND RETAINING THIS CONFIRMATIONd AND SELLER. BUYER SHALL ME DEEMED TO HAVE AS- WITHOUT OBJECTION FOR TEN DAYS
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NASA Astrophysics Data System (ADS)
Martinez Mateo, Isidoro Jose
Mould materials for injection moulding of polymers and polymer-matrix composites represent a relevant industrial economic sector due to the large quantity of pieces and components processed. The material selection for mould manufacturing, its composition and heat treatment, the hardening procedures and machining and finishing processes determine the service performance and life of the mould. In the first part of the present study, the relationship between the hardness and microstructure and the wear resistance of mould steels from large blocks has been studied by pin-on-disc tests, studying the main wear mechanisms. In order to determine the surface damage on mould steels under real injection conditions, different commercial steels have been studied by measuring the variation of surface roughness with the number of injected pieces with different reinforcement percentages and different mould geometries, by using optical profilometry and scanning electron microscopy techniques. It was important to determine the variation of surface roughness of the moulded pieces with the number of injection operations. The materials used were polybutyleneterephthalate pure and reinforced with either 20% or 50% glass fibre. For the different mould designs, the evolution of the glass fibre orientation with injection flow has been determined by image analysis and related to roughness changes and surface damage, both of the composite parts and of the mould steel surface. Finally, the abrasion resistance of the composite parts has been studied by scratch tests as a function of the number of injected parts and of the scratch direction with respect to injection flow and glass fibre orientation. Los materiales para moldes de inyeccion de polimeros y materiales compuestos representan un sector economicamente muy relevante debido al gran aumento del numero de componentes fabricados a partir de materiales polimericos obtenidos mediante moldeo por inyeccion. La seleccion del material para la fabricacion del molde, tienen una gran influencia sobre su comportamiento en servicio a lo largo de la vida util del molde. En la primera parte del presente estudio, a partir de ensayos punzon sobre disco, se ha determinado la relacion entre la resistencia al desgaste y la dureza de aceros para moldes obtenidos a partir de bloques de gran espesor, estudiando los principales mecanismos de desgaste que tienen lugar. A continuacion, con el fin de determinar el dano superficial que sufren los aceros para moldes en condiciones reales de inyeccion, se han estudiado distintos tipos de aceros utilizados comercialmente en moldes de inyeccion de polimeros y materiales compuestos, seleccionando las condiciones de operacion para determinar la variacion de la rugosidad superficial del acero en funcion del material inyectado, del numero de operaciones sucesivas de inyeccion y de la orientacion del flujo de inyeccion, mediante tecnicas de perfilometria optica y microscopia electronica de barrido. Ademas del dano superficial sufrido por el acero con el numero de piezas inyectadas, tambien se ha determinado la evolucion de la rugosidad superficial de los materiales inyectados, polibutilentereftalato (PBT) puro y materiales compuestos derivados de PBT por adicion de un 20 o un 50% en peso de fibra de vidrio. En el caso de las piezas inyectadas, se ha caracterizado su microestructura en funcion del flujo de inyeccion y de la densidad de fibra, se han determinado sus propiedades termicas y dinamico-mecanicas, asi como la variacion de la rugosidad superficial de las piezas inyectadas con el numero de operaciones de inyeccion y con la geometria de las distintas secciones de las piezas. Finalmente, se ha evaluado la resistencia a la abrasion de PBT reforzado con un 50% de fibra, en funcion del numero de piezas inyectadas y de la direccion de rayado con respecto a la orientacion del flujo de inyeccion.
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Traditional environmental mold analysis is based-on microscopic observations and counting of mold structures collected from the air on a sticky surface or culturing of molds on growth media for identification and quantification. A DNA-based method of mold analysis called mol...
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Development of New Laser Protective Dyes. Phase 2.
DYE LASERS, PROTECTION, LASERS, DYES , HAZARDS, SYNTHESIS, EYE SAFETY, OPTICAL MATERIALS, PLASTICS, LENSES, THERMAL STABILITY, CYANINE DYES , POLYCARBONATES, INJECTION MOLDING, NEAR INFRARED RADIATION, FLUORENES.
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A senior manufacturing laboratory for determining injection molding process capability
NASA Technical Reports Server (NTRS)
Wickman, Jerry L.; Plocinski, David
1992-01-01
The following is a laboratory experiment designed to further understanding of materials science. This subject material is directed at an upper level undergraduate/graduate student in an Engineering or Engineering Technology program. It is assumed that the student has a thorough understanding of the process and quality control. The format of this laboratory does not follow that which is normally recommended because of the nature of process capability and that of the injection molding equipment and tooling. This laboratory is instead developed to be used as a point of departure for determining process capability for any process in either a quality control laboratory or a manufacturing environment where control charts, process capability, and experimental or product design are considered important topics.
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Data characterizing tensile behavior of cenosphere/HDPE syntactic foam.
Kumar, B R Bharath; Doddamani, Mrityunjay; Zeltmann, Steven E; Gupta, Nikhil; Ramakrishna, Seeram
2016-03-01
The data set presented is related to the tensile behavior of cenosphere reinforced high density polyethylene syntactic foam composites "Processing of cenosphere/HDPE syntactic foams using an industrial scale polymer injection molding machine" (Bharath et al., 2016) [1]. The focus of the work is on determining the feasibility of using an industrial scale polymer injection molding (PIM) machine for fabricating syntactic foams. The fabricated syntactic foams are investigated for microstructure and tensile properties. The data presented in this article is related to optimization of the PIM process for syntactic foam manufacture, equations and procedures to develop theoretical estimates for properties of cenospheres, and microstructure of syntactic foams before and after failure. Included dataset contains values obtained from the theoretical model.
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Data characterizing tensile behavior of cenosphere/HDPE syntactic foam
Kumar, B.R. Bharath; Doddamani, Mrityunjay; Zeltmann, Steven E.; Gupta, Nikhil; Ramakrishna, Seeram
2016-01-01
The data set presented is related to the tensile behavior of cenosphere reinforced high density polyethylene syntactic foam composites “Processing of cenosphere/HDPE syntactic foams using an industrial scale polymer injection molding machine” (Bharath et al., 2016) [1]. The focus of the work is on determining the feasibility of using an industrial scale polymer injection molding (PIM) machine for fabricating syntactic foams. The fabricated syntactic foams are investigated for microstructure and tensile properties. The data presented in this article is related to optimization of the PIM process for syntactic foam manufacture, equations and procedures to develop theoretical estimates for properties of cenospheres, and microstructure of syntactic foams before and after failure. Included dataset contains values obtained from the theoretical model. PMID:26937472
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Recovery of polypropylene from spent lead-acid batteries
DOE Office of Scientific and Technical Information (OSTI.GOV)
Stout, M.E.
1995-12-31
The recovery of the constituent components of spent lead-acid batteries was pioneered in the early 1970`s by M.A. Industries, Inc. M.A.`s main reason for research and development in this area was to recover the polypropylene casings for use as feed stock in their injection molding plants. At that time spent and reject casings were either disposed of or being fed with the lead bearing materials into the smelting process. M.A. has since developed, built and operated a plant for the conversion of scrap casing into reusable copolymer resins. The system is composed of washing, sizing, extrusion and pelletizing the polymermore » into a form which is ready to be injection molded into new products.« less
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Effect of mold designs on molten metal behaviour in high-pressure die casting
NASA Astrophysics Data System (ADS)
Ibrahim, M. D.; Rahman, M. R. A.; Khan, A. A.; Mohamad, M. R.; Suffian, M. S. Z. M.; Yunos, Y. S.; Wong, L. K.; Mohtar, M. Z.
2017-04-01
This paper presents a research study conducted in a local automotive component manufacturer that produces aluminium alloy steering housing local and global markets. This study is to investigate the effect of design modification of mold in die casting as to improve the production rate. Design modification is carried out on the casting shot of the mold. Computer flow simulation was carried out to study the flow of molten metal in the mold with respect to the mold design modification. The design parameters of injection speed, die temperature and clamping force has been included in the study. The result of the simulation showed that modifications of casting shot give significant impact towards the molten flow behaviour in casting process. The capabilities and limitations of die casting process simulation to conduct defect analysis had been optimized. This research will enhance the efficiency of the mass production of the industry of die casting with the understanding of defect analysis, which lies on the modification of the mold design, a way early in its stages of production.
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USDA-ARS?s Scientific Manuscript database
Dried Distillers Grain with Solubles (DDGS) is evaluated as a bio-based fiber reinforcement. Injection molded composites of high density polyethylene (HDPE), 25% by weight of DDGS, and either 5% of 0% by weight of maleated polyethylene (MAPE) were produced by twin screw compounding and injection mo...
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DOE Office of Scientific and Technical Information (OSTI.GOV)
Nguyen, Ba Nghiep; Fifield, Leonard S.; Wang, Jin
2016-06-01
This project aimed to integrate, optimize, and validate the fiber orientation and length distribution models previously developed and implemented in the Autodesk® Simulation Moldflow® Insight (ASMI) software package for injection-molded long-carbon-fiber (LCF) thermoplastic composite structures. The project was organized into two phases. Phase 1 demonstrated the ability of the advanced ASMI package to predict fiber orientation and length distributions in LCF/polypropylene (PP) and LCF/polyamide-6, 6 (PA66) plaques within 15% of experimental results. Phase 2 validated the advanced ASMI package by predicting fiber orientation and length distributions within 15% of experimental results for a complex three-dimensional (3D) Toyota automotive part injection-moldedmore » from LCF/PP and LCF/PA66 materials. Work under Phase 2 also included estimate of weight savings and cost impacts for a vehicle system using ASMI and structural analyses of the complex part. The present report summarizes the completion of Phases 1 and 2 work activities and accomplishments achieved by the team comprising Pacific Northwest National Laboratory (PNNL); Purdue University (Purdue); Virginia Polytechnic Institute and State University (Virginia Tech); Autodesk, Inc. (Autodesk); PlastiComp, Inc. (PlastiComp); Toyota Research Institute North America (Toyota); Magna Exteriors and Interiors Corp. (Magna); and University of Illinois. Figure 1 illustrates the technical approach adopted in this project that progressed from compounding LCF/PP and LCF/PA66 materials, to process model improvement and implementation, to molding and modeling LCF/PP and LCF/PA66 plaques. The lessons learned from the plaque study and the successful validation of improved process models for fiber orientation and length distributions for these plaques enabled the project to go to Phase 2 to mold, model, and optimize the 3D complex part.« less
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Critical fiber length technique for composite manufacturing processes
DOE Office of Scientific and Technical Information (OSTI.GOV)
Sivley, G.N.; Vandiver, T.L.; Dougherty, N.S.
1996-12-31
An improved injection technique for composite structures has been cooperatively developed by the U.S. Army Missile Command (MICOM) and Rockwell International (RI). This process simultaneously injects chopped fiberglass fibers and an epoxy resin matrix into a mold. Four injection techniques: (1){open_quotes}Little Willie{close_quotes} RTM system, (2) Pressure Vat system, (3) Pressure Vat system with vacuum assistance, and (4) Injection gun system, were investigated for use with a 304.8 mm x 304.8 mm x 5.08 mm (12 in x 12 in x 0.2 in) flat plaque mold. The driving factors in the process optimization included: fiber length, fiber weight, matrix viscosity, injectionmore » pressure, flow rate, and tool design. At fiber weights higher than 30 percent, the injection gun appears to have advantages over the other systems investigated. Results of an experimental investigation are reviewed in this paper. The investigation of injection techniques is the initial part of the research involved in a developing process, {open_quotes}Critical Fiber Length Technique{close_quotes}. This process will use the data collected in injection experiment along with mechanical properties derived from coupon test data to be incorporated into a composite material design code. The {open_quotes}Critical Fiber Length Technique{close_quotes} is part of a Cooperative Research and Development Agreement (CRADA) established in 1994 between MICOM and RI.« less
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Flow behavior in liquid molding
NASA Technical Reports Server (NTRS)
Hunston, D.; Phelan, F.; Parnas, R.
1992-01-01
The liquid molding (LM) process for manufacturing polymer composites with structural properties has the potential to significantly lower fabrication costs and increase production rates. LM includes both resin transfer molding and structural reaction injection molding. To achieve this potential, however, the underlying science base must be improved to facilitate effective process optimization and implementation of on-line process control. The National Institute of Standards and Technology (NIST) has a major program in LM that includes materials characterization, process simulation models, on-line process monitoring and control, and the fabrication of test specimens. The results of this program are applied to real parts through cooperative projects with industry. The key feature in the effort is a comprehensive and integrated approach to the processing science aspects of LM. This paper briefly outlines the NIST program and uses several examples to illustrate the work.
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Additive manufacturing of near-net-shape bonded magnets: Prospects and challenges
Li, Ling; Post, Brian; Kunc, Vlastimil; ...
2017-01-03
Additive manufacturing (AM) or 3D printing is well known for producing arbitrary shaped parts without any tooling required, offering a promising alternative to the conventional injection molding method to fabricate near-net-shaped magnets. In order to determine their applicability in the fabrication of Nd-Fe-B bondedmagnets, we compare two 3D printing technologies, namely binder jetting and material extrusion. Some prospects and challenges of these state-of-the-art technologies for large-scale industrial applications will be discussed.
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Raut, Anjana; Rao, Polsani Laxman; Vikas, B V J; Ravindranath, T; Paradkar, Archana; Malakondaiah, G
2013-01-01
Acrylic resins have been in the center stage of Prosthodontics for more than half a century. The flexural fatigue failure of denture base materials is the primary mode of clinical failure. Hence there is a need for superior physical and mechanical properties. This in vitro study compared the transverse strength of specimens of thermopressed injection-molded and conventional compression-molded polymethylmethacrylate polymers and examined the morphology and microstructure of fractured acrylic specimens. The following denture base resins were examined: Brecrystal (Thermopressed injection-molded, modified polymethylmethacrylate) and Pyrax (compression molded, control group). Specimens of each material were tested according to the American Society for Testing and Materials standard D790-03 for flexural strength testing of reinforced plastics and subsequently examined under SEM. The data was analyzed with Student unpaired t test. Flexural strength of Brecrystal (82.08 ± 1.27 MPa) was significantly higher than Pyrax (72.76 ± 0.97 MPa). The tested denture base materials fulfilled the requirements regarding flexural strength (>65 MPa). The scanning electron microscopy image of Brecrystal revealed a ductile fracture with crazing. The fracture pattern of control group specimens exhibited poorly defined crystallographic planes with a high degree of disorganization. Flexural strength of Brecrystal was significantly higher than the control group. Brecrystal showed a higher mean transverse strength value of 82.08 ± 1.27 MPa and a more homogenous pattern at microscopic level. Based on flexural strength properties and handling characteristics, Brecrystal may prove to be an useful alternative to conventional denture base resins.
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Alavi, Shiva; Kachuie, Marzie
2017-01-01
Background: This study was conducted to assess the hardness of orthodontic brackets produced by metal injection molding (MIM) and conventional methods and different orthodontic wires (stainless steel, nickel-titanium [Ni-Ti], and beta-titanium alloys) for better clinical results. Materials and Methods: A total of 15 specimens from each brand of orthodontic brackets and wires were examined. The brackets (Elite Opti-Mim which is produced by MIM process and Ultratrimm which is produced by conventional brazing method) and the wires (stainless steel, Ni-Ti, and beta-titanium) were embedded in epoxy resin, followed by grinding, polishing, and coating. Then, X-ray energy dispersive spectroscopy (EDS) microanalysis was applied to assess their elemental composition. The same specimen surfaces were repolished and used for Vickers microhardness assessment. Hardness was statistically analyzed with Kruskal–Wallis test, followed by Mann–Whitney test at the 0.05 level of significance. Results: The X-ray EDS analysis revealed different ferrous or co-based alloys in each bracket. The maximum mean hardness values of the wires were achieved for stainless steel (SS) (529.85 Vickers hardness [VHN]) versus the minimum values for beta-titanium (334.65 VHN). Among the brackets, Elite Opti-Mim exhibited significantly higher VHN values (262.66 VHN) compared to Ultratrimm (206.59 VHN). VHN values of wire alloys were significantly higher than those of the brackets. Conclusion: MIM orthodontic brackets exhibited hardness values much lower than those of SS orthodontic archwires and were more compatible with NiTi and beta-titanium archwires. A wide range of microhardness values has been reported for conventional orthodontic brackets and it should be considered that the manufacturing method might be only one of the factors affecting the mechanical properties of orthodontic brackets including hardness. PMID:28928783
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Fabrication and Characterization of High Temperature Resin/Carbon Nanofiber Composites
NASA Technical Reports Server (NTRS)
Ghose, Sayata; Watson, Kent A.; Working, Dennis C.; Criss, Jim M.; Siochi, Emilie J.; Conell, John W.
2005-01-01
As part of ongoing efforts to develop multifunctional advanced composites, blends of PETI-330 and carbon nanofibers (CNF) were prepared and characterized. Dry mixing techniques were employed and the effect of CNF loading level on melt viscosity was determined. The resulting powders were characterized for degree of mixing, thermal and rheological properties. Based on the characterization results, samples containing 30 and 40 wt% CNF were scaled up to approx.300 g and used to fabricate moldings 10.2 cm x 15.2 cm x 0.32 cm thick. The moldings were fabricated by injecting the mixtures at 260-280 C into a stainless steel tool followed by curing for 1 h at 371 C. The tool was designed to impart high shear during the injection process in an attempt to achieve some alignment of CNFs in the flow direction. Moldings were obtained that were subsequently characterized for thermal, mechanical and electrical properties. The degree of dispersion and alignment of CNFs were investigated using high-resolution scanning electron microscopy. The preparation and preliminary characterization of PETI-330/CNF composites will be discussed.
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3D Fiber Orientation Simulation for Plastic Injection Molding
NASA Astrophysics Data System (ADS)
Lin, Baojiu; Jin, Xiaoshi; Zheng, Rong; Costa, Franco S.; Fan, Zhiliang
2004-06-01
Glass fiber reinforced polymer is widely used in the products made using injection molding processing. The distribution of fiber orientation inside plastic parts has direct effects on quality of molded parts. Using computer simulation to predict fiber orientation distribution is one of most efficient ways to assist engineers to do warpage analysis and to find a good design solution to produce high quality plastic parts. Fiber orientation simulation software based on 2-1/2D (midplane /Dual domain mesh) techniques has been used in industry for a decade. However, the 2-1/2D technique is based on the planar Hele-Shaw approximation and it is not suitable when the geometry has complex three-dimensional features which cannot be well approximated by 2D shells. Recently, a full 3D simulation software for fiber orientation has been developed and integrated into Moldflow Plastics Insight 3D simulation software. The theory for this new 3D fiber orientation calculation module is described in this paper. Several examples are also presented to show the benefit in using 3D fiber orientation simulation.
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Improved silicon carbide for advanced heat engines
NASA Technical Reports Server (NTRS)
Whalen, Thomas J.; Mangels, J. A.
1986-01-01
The development of silicon carbide materials of high strength was initiated and components of complex shape and high reliability were formed. The approach was to adapt a beta-SiC powder and binder system to the injection molding process and to develop procedures and process parameters capable of providing a sintered silicon carbide material with improved properties. The initial effort was to characterize the baseline precursor materials, develop mixing and injection molding procedures for fabricating test bars, and characterize the properties of the sintered materials. Parallel studies of various mixing, dewaxing, and sintering procedures were performed in order to distinguish process routes for improving material properties. A total of 276 modulus-of-rupture (MOR) bars of the baseline material was molded, and 122 bars were fully processed to a sinter density of approximately 95 percent. Fluid mixing techniques were developed which significantly reduced flaw size and improved the strength of the material. Initial MOR tests indicated that strength of the fluid-mixed material exceeds the baseline property by more than 33 percent. the baseline property by more than 33 percent.
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High Temperature Resin/Carbon Nanotube Composite Fabrication
NASA Technical Reports Server (NTRS)
Ghose, Sayata; Watson, Kent A.; Sun, Keun J.; Criss, Jim M.; Siochi, Emilie J.; Connell, John W.
2006-01-01
For the purpose of incorporating multifunctionality into advanced composites, blends of phenylethynyl terminated imides-330 (PETI-330) and multi-walled carbon nanotubes (MWCNTs) were prepared, characterized and fabricated into moldings. PETI-330/MWCNT mixtures were prepared at concentrations ranging from 3 to 25 weight percent by dry mixing the components in a ball mill. The resulting powders were characterized for degree of mixing, thermal and rheological properties. Based on the characterization results, PETI-330/MWCNT samples were scaled up to approximately 300 g and used to fabricate moldings by injecting the mixtures at 260-280 deg C into a stainless steel tool followed by curing for 1 h at 371 deg C. The tool was designed to impart a degree of shear during the injection process in an attempt to achieve some alignment of the MWCNTs in the flow direction. Obtained moldings were subsequently characterized for thermal, mechanical, and electrical properties. The degree of dispersion and alignment of MWCNTs were investigated using high-resolution scanning electron microscopy. The preparation and preliminary characterization of PETI-330/MWCNT composites will be discussed.
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NASA Astrophysics Data System (ADS)
Siepmann, Jens P.; Wortberg, Johannes; Heinzler, Felix A.
2016-03-01
The injection molding process is mandatorily influenced by the viscosity of the material. By varying the material batch the viscosity of the polymer changes. For the process and part quality the initial conditions of the material in addition to the processing parameters define the process and product quality. A high percentage of technical polymers processed in injection molding is refined in a follow-up production step, for example electro plating. Processing optimized for electro plating often requires avoiding high shear stresses by using low injection speed and pressure conditions. Therefore differences in the material charges' viscosity occur especially in the quality related low shear rate area. These differences and quality related influences can be investigated by high detail rheological analysis and process simulation based on adapted material describing models. Differences in viscosity between batches can be detected by measurements with high-pressure-capillary-rheometers or oscillatory rheometers for low shear rates. A combination of both measurement techniques is possible by the Cox-Merz-Relation. The detected differences in the rheological behavior of both charges are summarized in two material behavior describing model approaches and added to the simulation. In this paper the results of processing-simulations with standard filling parameters are presented with two ABS charges. Part quality defining quantities such as temperature, pressure and shear stress are investigated and the influence of charge variations is pointed out with respect to electro plating quality demands. Furthermore, the results of simulations with a new quality related process control are presented and compared to the standard processing.
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In-situ stabilization of radioactive zirconium swarf
Hess, C.C.
1999-08-31
The method for treating ignitable cutting swarf in accordance with the present invention involves collecting cutting swarf in a casting mold underwater and injecting a binder mixture comprising vinyl ester styrene into the vessel to fill void volume; and form a mixture comprising swarf and vinyl ester styrene; and curing the mixture. The method is especially useful for stabilizing the ignitable characteristics of radioactive zirconium cutting swarf, and can be used to solidify zirconium swarf, or other ignitable finely divided material, underwater. The process could also be performed out of water with other particulate wastes. 6 figs.
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DOE Office of Scientific and Technical Information (OSTI.GOV)
Huang, Runze; Riddle, Matthew E.; Graziano, Diane
Additive manufacturing (AM) holds great potentials in enabling superior engineering functionality, streamlining supply chains, and reducing life cycle impacts compared to conventional manufacturing (CM). This study estimates the net changes in supply-chain lead time, life cycle primary energy consumption, greenhouse gas (GHG) emissions, and life cycle costs (LCC) associated with AM technologies for the case of injection molding, to shed light on the environmental and economic advantages of a shift from international or onshore CM to AM in the United States. A systems modeling framework is developed, with integrations of lead-time analysis, life cycle inventory analysis, LCC model, and scenariosmore » considering design differences, supply-chain options, productions, maintenance, and AM technological developments. AM yields a reduction potential of 3% to 5% primary energy, 4% to 7% GHG emissions, 12% to 60% lead time, and 15% to 35% cost over 1 million cycles of the injection molding production depending on the AM technology advancement in future. The economic advantages indicate the significant role of AM technology in raising global manufacturing competitiveness of local producers, while the relatively small environmental benefits highlight the necessity of considering trade-offs and balance techniques between environmental and economic performances when AM is adopted in the tooling industry. The results also help pinpoint the technological innovations in AM that could lead to broader benefits in future.« less
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Huang, Runze; Riddle, Matthew E.; Graziano, Diane; ...
2017-08-26
Additive manufacturing (AM) holds great potentials in enabling superior engineering functionality, streamlining supply chains, and reducing life cycle impacts compared to conventional manufacturing (CM). This study estimates the net changes in supply-chain lead time, life cycle primary energy consumption, greenhouse gas (GHG) emissions, and life cycle costs (LCC) associated with AM technologies for the case of injection molding, to shed light on the environmental and economic advantages of a shift from international or onshore CM to AM in the United States. A systems modeling framework is developed, with integrations of lead-time analysis, life cycle inventory analysis, LCC model, and scenariosmore » considering design differences, supply-chain options, productions, maintenance, and AM technological developments. AM yields a reduction potential of 3% to 5% primary energy, 4% to 7% GHG emissions, 12% to 60% lead time, and 15% to 35% cost over 1 million cycles of the injection molding production depending on the AM technology advancement in future. The economic advantages indicate the significant role of AM technology in raising global manufacturing competitiveness of local producers, while the relatively small environmental benefits highlight the necessity of considering trade-offs and balance techniques between environmental and economic performances when AM is adopted in the tooling industry. The results also help pinpoint the technological innovations in AM that could lead to broader benefits in future.« less
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The effect of cycling deflection on the injection-molded thermoplastic denture base resins.
Hamanaka, Ippei; Iwamoto, Misa; Lassila, Lippo Vj; Vallittu, Pekka K; Shimizu, Hiroshi; Takahashi, Yutaka
2016-01-01
The aim of this study was to evaluate the effect of cycling deflection on the flexural behavior of injection-molded thermoplastic resins. Six injection-molded thermoplastic resins (two polyamides, two polyesters, one polycarbonate, one polymethyl methacrylate) and, as a control, a conventional heat-polymerized denture based polymer of polymethyl methacrylate (PMMA) were used in this study. The cyclic constant magnitude (1.0 mm) of 5000 cycles was applied using a universal testing machine to demonstrate plasticization of the polymer. Loading was carried out in water at 23ºC with eight specimens per group (n = 8). Cycling load (N) and deformation (mm) were measured. Force required to deflect the specimens during the first loading cycle and final loading cycle was statistically significantly different (p < 0.05) with one polyamide based polymer (Valplast) and PMMA based polymers (Acrytone and Acron). The other polyamide based polymer (LucitoneFRS), polyester based polymers (EstheShot and EstheShotBright) and polycarbonate based polymer (ReigningN) did not show significant differences (p > 0.05). None of the materials fractured during the loading test. One polyamide based polymer (Valplast) displayed the highest deformation and PMMA based polymers (Acrytone and Acron) exhibited the second highest deformation among the denture base materials. It can be concluded that there were considerable differences in the flexural behavior of denture base polymers. This may contribute to the fatigue resistance of the materials.
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NASA Astrophysics Data System (ADS)
Nuruzzaman, D. M.; Kusaseh, N. M.; Chowdhury, M. A.; Rahman, N. A. N. A.; Oumer, A. N.; Fatchurrohman, N.; Iqbal, A. K. M. A.; Ismail, N. M.
2018-04-01
In this research study, glass fiber (GF) reinforced polypropylene (PP)-nylon 6 (PA6) polymer blend composites were prepared using injection molding process. Specimens of four different compositions such as 80%PP+20%PA6, 80%PP+18%PA6+2%GF, 80%PP+16%PA6+4%GF and 80%PP+14%PA6+6%GF were prepared. In the injection molding process, suitable process parameters were selected depending on the type of composite specimen in producing defects free dog bone shaped specimens. Flexure and impact tests were carried out according to ASTM standard. The important flexure properties such as flexural modulus, flexural yield strength, flexural strength and flexural strain were investigated. The obtained results revealed that flexural modulus of 80%PP+20%PA6 polymer blend is the lowest and the polymer blend composite shows steadily improved modulus as the glass fiber content is increased. Results also showed that flexural strength of pure polymer blend is the lowest but it improves gradually when the glass fiber content is increased. Impact test results revealed that impact strength of 80%PP+20%PA6 polymer blend is the highest whereas all the composites show reduced impact strength or toughness. It is noticed that 80%PP+14%PA6+6%GF composite exhibits the lowest impact strength.
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NASA Astrophysics Data System (ADS)
Wibowo, Y. T.; Baskoro, S. Y.; Manurung, V. A. T.
2018-02-01
Plastic based products spread all over the world in many aspects of life. The ability to substitute other materials is getting stronger and wider. The use of plastic materials increases and become unavoidable. Plastic based mass production requires injection process as well Mold. The milling process of plastic mold steel material was done using HSS End Mill cutting tool that is widely used in a small and medium enterprise for the reason of its ability to be re sharpened and relatively inexpensive. Study on the effect of the geometry tool states that it has an important effect on the quality improvement. Cutting speed, feed rate, depth of cut and radii are input parameters beside to the tool path strategy. This paper aims to investigate input parameter and cutting tools behaviors within some different tool path strategy. For the reason of experiments efficiency Taguchi method and ANOVA were used. Response studied is surface roughness and cutting behaviors. By achieving the expected quality, no more additional process is required. Finally, the optimal combination of machining parameters will deliver the expected roughness and of course totally reduced cutting time. However actually, SMEs do not optimally use this data for cost reduction.
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NASA Astrophysics Data System (ADS)
Haoyi, Li; Weimin, Yang; Hongbo, Chen; Jing, Tan; Pengcheng, Xie
2016-03-01
A concept of Differential-Integral (DI) method applied in polymer processing and molding was proposed, which included melt DI injection molding, DI nano-composites extrusion molding and melt differential electrospinning principle and equipment. Taking the melt differential electrospinning for example to introduce the innovation research progress, two methods preparing polymer ultrafine fiber have been developed: solution electro-spinning and melt electro-spinning, between which solution electro-spinning is much simpler to realize in lab. More than 100 institutions have endeavored to conduct research on it and more than 30 thousand papers have been published. However, its industrialization was restricted to some extend because of the existence of toxic solvent during spinning process and poor mechanical strength of resultant fibers caused by small pores on fiber surface. Solvent-free melt electrospinning is environmentally friendly and highly productive. However, problems such as the high melt viscosity, thick fiber diameter and complex equipment makes it relatively under researched compared with solution electrospinning. With the purpose of solving the shortage of traditional electro-spinning equipment with needles or capillaries, a melt differential electro-spinning method without needles or capillaries was firstly proposed. Nearly 50 related patents have been applied since 2005, and systematic method innovations and experimental studies have also been conducted. The prepared fiber by this method had exhibited small diameter and smooth surface. The average fiber diameter can reach 200-800 nm, and the single nozzle can yield two orders of magnitude more than the capillaries. Based on the above principle, complete commercial techniques and equipment have been developed to produce ultra-fine non-woven fabrics for the applications in air filtration, oil spill recovery and water treatment, etc.
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Occupational exposure to bisphenol A (BPA) in a plastic injection molding factory in Malaysia.
Kouidhi, Wided; Thannimalay, Letchumi; Soon, Chen Sau; Ali Mohd, Mustafa
2017-07-14
The purpose of this study has been to assess ambient bisphenol A (BPA) levels in workplaces and urine levels of workers and to establish a BPA database for different populations in Malaysia. Urine samples were collected from plastic factory workers and from control subjects after their shift. Air samples were collected using gas analyzers from 5 sampling positions in the injection molding unit work area and from ambient air. The level of BPA in airborne and urine samples was quantified by the gas chromatography mass spectrometry - selected ion monitoring (GCMS-SIM) analysis. Bisphenol A was detected in the median range of 8-28.3 ng/m³ and 2.4-3.59 ng/m³ for the 5 sampling points in the plastic molding factory and in the ambient air respectively. The median urinary BPA concentration was significantly higher in the workers (3.81 ng/ml) than in control subjects (0.73 ng/ml). The urinary BPA concentration was significantly associated with airborne BPA levels (ρ = 0.55, p < 0.01). Our findings provide the first evidence that workers in a molding factory in Malaysia are occupationally exposed to BPA. Int J Occup Med Environ Health 2017;30(5):743-750. This work is available in Open Access model and licensed under a CC BY-NC 3.0 PL license.
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Melocchi, Alice; Loreti, Giulia; Del Curto, Maria Dorly; Maroni, Alessandra; Gazzaniga, Andrea; Zema, Lucia
2015-06-01
The exploitation of hot-melt extrusion and injection molding for the manufacturing of immediate-release (IR) tablets was preliminarily investigated in view of their special suitability for continuous manufacturing, which represents a current goal of pharmaceutical production because of its possible advantages in terms of improved sustainability. Tablet-forming agents were initially screened based on processability by single-screw extruder and micromolding machine as well as disintegration/dissolution behavior of extruded/molded prototypes. Various polymers, such as low-viscosity hydroxypropylcellulose, polyvinyl alcohol, polyvinyl alcohol-polyethylene glycol graft copolymer, various sodium starch glycolate grades (e.g., Explotab(®) CLV) that could be processed with no need for technological aids, except for a plasticizer, were identified. Furthermore, the feasibility of both extruded and molded IR tablets from low-viscosity hydroxypropylcellulose or Explotab(®) CLV was assessed. Explotab(®) CLV, in particular, showed thermoplastic properties and a very good aptitude as a tablet-forming agent, starting from which disintegrating tablets were successfully obtained by either techniques. Prototypes containing a poorly soluble model drug (furosemide), based on both a simple formulation (Explotab(®) CLV and water/glycerol as plasticizers) and formulations including dissolution/disintegration adjuvants (soluble and effervescent excipients) were shown to fulfill the USP 37 dissolution requirements for furosemide tablets. © 2015 Wiley Periodicals, Inc. and the American Pharmacists Association.
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Enteric-coating of pulsatile-release HPC capsules prepared by injection molding.
Macchi, E; Zema, L; Maroni, A; Gazzaniga, A; Felton, L A
2015-04-05
Capsular devices based on hydroxypropyl cellulose (Klucel® LF) intended for pulsatile release were prepared by injection molding (IM). In the present work, the possibility of exploiting such capsules for the development of colonic delivery systems based on a time-dependent approach was evaluated. For this purpose, it was necessary to demonstrate the ability of molded cores to undergo a coating process and that coated systems yield the desired performance (gastric resistance). Although no information was available on the coating of IM substrates, some issues relevant to that of commercially-available capsules are known. Thus, preliminary studies were conducted on molded disks for screening purposes prior to the spray-coating of HPC capsular cores with Eudragit® L 30 D 55. The ability of the polymeric suspension to wet the substrate, spread, start penetrating and initiate hydration/swelling, as well as to provide a gastroresistant barrier was demonstrated. The coating of prototype HPC capsules was carried out successfully, leading to coated systems with good technological properties and able to withstand the acidic medium with no need for sealing at the cap/body joint. Such systems maintained the original pulsatile release performance after dissolution of the enteric film in pH 6.8 fluid. Therefore, they appeared potentially suitable for the development of a colon delivery platform based on a time-dependent approach. Copyright © 2015 Elsevier B.V. All rights reserved.
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Puri, Vibha; Brancazio, Dave; Desai, Parind M; Jensen, Keith D; Chun, Jung-Hoon; Myerson, Allan S; Trout, Bernhardt L
2017-11-01
The combination of hot-melt extrusion and injection molding (HME-IM) is a promising process technology for continuous manufacturing of tablets. However, there has been limited research on its application to formulate crystalline drug-containing immediate-release tablets. Furthermore, studies that have applied the HME-IM process to molded tablets have used a noncontinuous 2-step approach. The present study develops maltodextrin (MDX)-based extrusion-molded immediate-release tablets for a crystalline drug (griseofulvin) using an integrated twin-screw HME-IM continuous process. At 10% w/w drug loading, MDX was selected as the tablet matrix former based on a preliminary screen. Furthermore, liquid and solid polyols were evaluated for melt processing of MDX and for impact on tablet performance. Smooth-surfaced tablets, comprising crystalline griseofulvin solid suspension in the amorphous MDX-xylitol matrix, were produced by a continuous process on a twin-screw extruder coupled to a horizontally opening IM machine. Real-time HME process profiles were used to develop automated HME-IM cycles. Formulation adjustments overcame process challenges and improved tablet strength. The developed MDX tablets exhibited adequate strength and a fast-dissolving matrix (85% drug release in 20 min), and maintained performance on accelerated stability conditions. Copyright © 2017 American Pharmacists Association®. Published by Elsevier Inc. All rights reserved.
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Xu, Ling; Chen, Chen; Zhong, Gan-Ji; Lei, Jun; Xu, Jia-Zhuang; Hsiao, Benjamin S; Li, Zhong-Ming
2012-03-01
An easy approach was reported to achieve high mechanical properties of ultrahigh-molecular-weight polyethylene (UHMWPE)-based polyethylene (PE) blend for artificial joint application without the sacrifice of the original excellent wear and fatigue behavior of UHMWPE. The PE blend with desirable fluidity was obtained by melt mixing UHMWPE and low molecular weight polyethylene (LMWPE), and then was processed by a modified injection molding technology-oscillatory shear injection molding (OSIM). Morphological observation of the OSIM PE blend showed LMWPE contained well-defined interlocking shish-kebab self-reinforced superstructure. Addition of a small amount of long chain polyethylene (2 wt %) to LMWPE greatly induced formation of rich shish-kebabs. The ultimate tensile strength considerably increased from 27.6 MPa for conventional compression molded UHMWPE up to 78.4 MPa for OSIM PE blend along the flow direction and up to 33.5 MPa in its transverse direction. The impact strength of OSIM PE blend was increased by 46% and 7% for OSIM PE blend in the direction parallel and vertical to the shear flow, respectively. Wear and fatigue resistance were comparable to conventional compression molded UHMWPE. The superb performance of the OSIM PE blend was originated from formation of rich interlocking shish-kebab superstructure while maintaining unique properties of UHMWPE. The present results suggested the OSIM PE blend has high potential for artificial joint application. © 2012 American Chemical Society
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Batch fabrication of polymer microfluidic cartridges for QCM sensor packaging by direct bonding
NASA Astrophysics Data System (ADS)
Sandström, Niklas; Zandi Shafagh, Reza; Gylfason, Kristinn B.; Haraldsson, Tommy; van der Wijngaart, Wouter
2017-12-01
Quartz crystal microbalance (QCM) sensing is an established technique commonly used in laboratory based life-science applications. However, the relatively complex, multi-part design and multi-step fabrication and assembly of state-of-the-art QCM cartridges make them unsuited for disposable applications such as point-of-care (PoC) diagnostics. In this work, we present the uncomplicated manufacturing of QCMs in polymer microfluidic cartridges. Our novel approach comprises two key innovations: the batch reaction injection molding of microfluidic parts; and the integration of the cartridge components by direct, unassisted bonding. We demonstrate molding of batches of 12 off-stoichiometry thiol-ene epoxy polymer (OSTE+) polymer parts in a single molding cycle using an adapted reaction injection molding process; and the direct bonding of the OSTE+ parts to other OSTE+ substrates, to printed circuit boards, and to QCMs. The microfluidic QCM OSTE+ cartridges were successfully evaluated in terms of liquid sealing as well as electrical properties, and the sensor performance characteristics are on par with those of a commercially available QCM biosensor cartridge. The simplified manufacturing of QCM sensors with maintained performance potentializes novel application areas, e.g. as disposable devices in a point of care setting. Moreover, our results can be extended to simplifying the fabrication of other microfluidic devices with multiple heterogeneously integrated components.
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NASA Astrophysics Data System (ADS)
Manas, David; Manas, Miroslav; Gajzlerova, Lenka; Ovsik, Martin; Kratky, Petr; Senkerik, Vojtěch; Skrobak, Adam; Danek, Michal; Manas, Martin
2015-09-01
The influence of beta radiation on the changes in the structure and selected properties (mechanical and thermal) was proved. Using low doses of beta radiation for 25% glass fiber filled polypropylene and its influence on the changes of micromechanical properties of surface layer has not been studied in detail so far. The specimens of 25% glass fiber filled PP were made by injection molding technology and irradiated by low doses of beta radiation (0, 15 and 33 kGy). The changes in the microstructure and micromechanical properties of surface layer were evaluated using FTIR, SEM, WAXS and instrumented microhardness test. The results of the measurements showed considerable increase in micromechanical properties (indentation hardness, indentation elastic modulus) when low doses of beta radiation are used.
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NASA Astrophysics Data System (ADS)
Jin, Chul Kyu; Kang, Chung Gil
2011-10-01
There are various methods for the fabrication of bipolar plates, but these are still limited to machining and stamping processes. High-pressure die casting (HPDC) is an ideal process for the manufacture of bipolar plates This study aims to investigate the formability of bipolar plates for polymer electrolyte membrane fuel cells (PEMFCs) fabricated by vacuum HPDC of an Al-Mg alloy (ALDC6). The cavity of the mold consisted of a thin-walled plate (200 mm × 200 mm × 0.8 mm) with a layer of serpentine channel (50 mm × 50 mm). The location and direction of the channel in the final mold design was determined by computational simulation (MAGMA soft). In addition, simulation results for different conditions of plunger stroke control were compared to those from actual die-casting experiments. Under a vacuum pressure of 35 kPa and for injection speeds of 0.3 and 2.5 m s-1 in the low and high speed regions, respectively, the samples had few casting defects. In addition, the hardness was higher and porosity in microstructure was less than those of the samples made under other injection speed conditions. In case of thin-walled plates, vacuum die casting is beneficial in terms of formability compared to conventional die casting.
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Mi, Hao-Yang; Salick, Max R; Jing, Xin; Jacques, Brianna R; Crone, Wendy C; Peng, Xiang-Fang; Turng, Lih-Sheng
2013-12-01
Polylactic acid (PLA) and thermoplastic polyurethane (TPU) are two kinds of biocompatible and biodegradable polymers that can be used in biomedical applications. PLA has rigid mechanical properties while TPU possesses flexible mechanical properties. Blended TPU/PLA tissue engineering scaffolds at different ratios for tunable properties were fabricated via twin screw extrusion and microcellular injection molding techniques for the first time. Multiple test methods were used to characterize these materials. Fourier transform infrared spectroscopy (FTIR) confirmed the existence of the two components in the blends; differential scanning calorimetry (DSC) and dynamic mechanical analysis (DMA) confirmed the immiscibility between the TPU and PLA. Scanning electron microscopy (SEM) images verified that, at the composition ratios studied, PLA was dispersed as spheres or islands inside the TPU matrix and that this phase morphology further influenced the scaffold's microstructure and surface roughness. The blends exhibited a large range of mechanical properties that covered several human tissue requirements. 3T3 fibroblast cell culture showed that the scaffolds supported cell proliferation and migration properly. Most importantly, this study demonstrated the feasibility of mass producing biocompatible PLA/TPU scaffolds with tunable microstructures, surface roughnesses, and mechanical properties that have the potential to be used as artificial scaffolds in multiple tissue engineering applications. © 2013.
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Liu, Shih-Jung; Chiang, Fu-Jun; Hsiao, Chao-Ying; Kau, Yi-Chuan; Liu, Kuo-Sheng
2010-10-01
The purpose of this report was to develop novel balloon-expandable self-lock drug-eluting poly(ε-caprolactone) stents. To fabricate the biodegradable stents, polycaprolactone (PCL) components were first fabricated by a lab-scale micro-injection molded machine. They were then assembled and hot-spot welded into mesh-like stents of 3 and 5 mm in diameters. A special geometry of the components was designed to self-lock the assembled stents and to resist the external pressure of the blood vessels after being expanded by balloons. Characterization of the biodegradable PCL stents was carried out. PCL stents exhibited comparable mechanical property to that of metallic stents. No significant collapse pressure reduction and weight loss of the stents were observed after being submerged in PBS for 12 weeks. In addition, the developed stent was coated with paclitaxel by a spray coating technique and the release characteristic of the drug was determined by an in vitro elution method. The high-performance liquid chromatography analysis showed that the biodegradable stents could release a high concentration of paclitaxel for more than 60 days. By adopting the novel techniques, we will be able to fabricate biodegradable drug-eluting PCL stents of different sizes for various cardiovascular applications.
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Mi, Hao-Yang; Salick, Max R.; Jing, Xin; Jacques, Brianna R.; Crone, Wendy C.; Peng, Xiang-Fang; Turng, Lih-Sheng
2015-01-01
Polylactic acid (PLA) and thermoplastic polyurethane (TPU) are two kinds of biocompatible and biodegradable polymers that can be used in biomedical applications. PLA has rigid mechanical properties while TPU possesses flexible mechanical properties. Blended TPU/PLA tissue engineering scaffolds at different ratios for tunable properties were fabricated via twin screw extrusion and microcellular injection molding techniques for the first time. Multiple test methods were used to characterize these materials. Fourier transform infrared spectroscopy (FTIR) confirmed the existence of the two components in the blends; differential scanning calorimetry (DSC) and dynamic mechanical analysis (DMA) confirmed the immiscibility between the TPU and PLA. Scanning electron microscopy (SEM) images verified that, at the composition ratios studied, PLA was dispersed as spheres or islands inside the TPU matrix and that this phase morphology further influenced the scaffold’s microstructure and surface roughness. The blends exhibited a large range of mechanical properties that covered several human tissue requirements. 3T3 fibroblast cell culture showed that the scaffolds supported cell proliferation and migration properly. Most importantly, this study demonstrated the feasibility of mass producing biocompatible PLA/TPU scaffolds with tunable microstructures, surface roughnesses, and mechanical properties that have the potential to be used as artificial scaffolds in multiple tissue engineering applications. PMID:24094186
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American Society of Composites, 32nd Technical Conference
DOE Office of Scientific and Technical Information (OSTI.GOV)
Aitharaju, Venkat; Yu, Hang; Zhao, Selina
Resin transfer molding (RTM) has become increasingly popular for the manufacturing of composite parts. To enable high volume manufacturing and obtain good quality parts at an acceptable cost to automotive industry, accurate process simulation tools are necessary to optimize the process conditions. Towards that goal, General Motors and the ESI-group are involved in developing a state of the art process simulation tool for composite manufacturing in a project supported by the Department of Energy. This paper describes the modeling of various stages in resin transfer molding such as resin injection, resin curing, and part distortion. An instrumented RTM system locatedmore » at the General Motors Research and Development center was used to perform flat plaque molding experiments. The experimental measurements of fill time, in-mold pressure versus time, cure variation with time, and part deformation were compared with the model predictions and very good correlations were observed.« less
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Zhou, Yi; Yu, Feilong; Deng, Hua; Huang, Yajiang; Li, Guangxian; Fu, Qiang
2017-06-29
The morphology evolution under shear during different processing is indeed an important issue regarding the phase morphology control as well as final physical properties of immiscible polymer blends. High-speed thin wall injection molding (HSTWIM) has recently been demonstrated as an effective method to prepare alternating multilayered structure. To understand the formation mechanism better and explore possible phase morphology for different blends under HSTWIM, the relationship between the morphology evolution of polymer blends based on polypropylene (PP) under HSTWIM and some intrinsic properties of polymer blends, including viscosity ratio, interfacial tension, and melt elasticity, is systematically investigated in this study. Blends based on PP containing polyethylene (PE), ethylene vinyl alcohol copolymer (EVOH), and polylactic acid (PLA) are used as examples. Compatibilizer has also been added into respective blends to alter their interfacial interaction. It is demonstrated that dispersed phase can be deformed into a layered-like structure if interfacial tension, viscosity ratio, and melt elasticity are relatively small. While some of these values are relatively large, these dispersed droplets are not easily deformed under HSTWIM, forming ellipsoidal or fiber-like structure. The addition of a moderate amount of compatibilizer into these blends is shown to be able to reduce interfacial tension and the size of dispersed phase, thus, allowing more deformation on the dispersed phase. Such a study could provide some guidelines on phase morphology control of immiscible polymer blends under shear during various processing methods.
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Resin film infusion mold tooling and molding method
NASA Technical Reports Server (NTRS)
Burgess, Roger (Inventor); Grossheim, Brian (Inventor); Mouradian, Karbis (Inventor); Thrash, Patrick J. (Inventor)
1999-01-01
A mold apparatus and method for resin film infusion molding including an outer mold tool having a facing sheet adapted to support a resin film and preform assembly. The facing sheet includes attachment features extending therefrom. An inner mold tool is positioned on the facing sheet to enclose the resin film and preform assembly for resin film infusion molding. The inner mold tool includes a plurality of mandrels positioned for engagement with the resin film and preform assembly. Each mandrel includes a slot formed therein. A plurality of locating bars cooperate with the slots and with the attachment features for locating the mandrels longitudinally on the outer mold tool.
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Alavi, Shiva; Kachuie, Marzie
2017-01-01
This study was conducted to assess the hardness of orthodontic brackets produced by metal injection molding (MIM) and conventional methods and different orthodontic wires (stainless steel, nickel-titanium [Ni-Ti], and beta-titanium alloys) for better clinical results. A total of 15 specimens from each brand of orthodontic brackets and wires were examined. The brackets (Elite Opti-Mim which is produced by MIM process and Ultratrimm which is produced by conventional brazing method) and the wires (stainless steel, Ni-Ti, and beta-titanium) were embedded in epoxy resin, followed by grinding, polishing, and coating. Then, X-ray energy dispersive spectroscopy (EDS) microanalysis was applied to assess their elemental composition. The same specimen surfaces were repolished and used for Vickers microhardness assessment. Hardness was statistically analyzed with Kruskal-Wallis test, followed by Mann-Whitney test at the 0.05 level of significance. The X-ray EDS analysis revealed different ferrous or co-based alloys in each bracket. The maximum mean hardness values of the wires were achieved for stainless steel (SS) (529.85 Vickers hardness [VHN]) versus the minimum values for beta-titanium (334.65 VHN). Among the brackets, Elite Opti-Mim exhibited significantly higher VHN values (262.66 VHN) compared to Ultratrimm (206.59 VHN). VHN values of wire alloys were significantly higher than those of the brackets. MIM orthodontic brackets exhibited hardness values much lower than those of SS orthodontic archwires and were more compatible with NiTi and beta-titanium archwires. A wide range of microhardness values has been reported for conventional orthodontic brackets and it should be considered that the manufacturing method might be only one of the factors affecting the mechanical properties of orthodontic brackets including hardness.
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NASA Astrophysics Data System (ADS)
Didier, Delaunay; Baptiste, Pignon; Nicolas, Boyard; Vincent, Sobotka
2018-05-01
Heat transfer during the cooling of a thermoplastic injected part directly affects the solidification of the polymer and consequently the quality of the part in term of mechanical properties, geometric tolerance and surface aspect. This paper proposes to mold designers a methodology based on analytical models to provide quickly the time to reach the ejection temperature depending of the temperature and the position of cooling channels. The obtained cooling time is the first step of the thermal conception of the mold. The presented methodology is dedicated to the determination of solidification time of a semi-crystalline polymer slab. It allows the calculation of the crystallization time of the part and is based on the analytical solution of the Stefan problem in a semi-infinite medium. The crystallization is then considered as a phase change with an effective crystallization temperature, which is obtained from Fast Scanning Calorimetry (FSC) results. The crystallization time is then corrected to take the finite thickness of the part into account. To check the accuracy of such approach, the solidification time is calculated by solving the heat conduction equation coupled to the crystallization kinetics of the polymer. The impact of the nature of the contact between the polymer and the mold is evaluated. The thermal contact resistance (TCR) appears as significant parameter that needs to be taken into account in the cooling time calculation. The results of the simplified model including or not TCR are compared in the case of a polypropylene (PP) with experiments carried out with an instrumented mold. Then, the methodology is applied for a part made with PolyEtherEtherKetone (PEEK).
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Hongtao, Li; Shichao, Chen; Yanjun, Han; Yi, Luo
2013-01-14
A feedback method combined with fitting technique based on variable separation mapping is proposed to design freeform optical systems for an extended LED source with prescribed illumination patterns, especially with uniform illuminance distribution. Feedback process performs well with extended sources, while fitting technique contributes not only to the decrease of pieces of sub-surfaces in discontinuous freeform lenses which may cause loss in manufacture, but also the reduction in the number of feedback iterations. It is proved that light control efficiency can be improved by 5%, while keeping a high uniformity of 82%, with only two feedback iterations and one fitting operation can improve. Furthermore, the polar angle θ and azimuthal angle φ is used to specify the light direction from the light source, and the (θ,φ)-(x,y) based mapping and feedback strategy makes sure that even few discontinuous sections along the equi-φ plane exist in the system, they are perpendicular to the base plane, making it eligible for manufacturing the surfaces using injection molding.
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NASA Astrophysics Data System (ADS)
Liu, Xiaohua; Zhou, Tianfeng; Zhang, Lin; Zhou, Wenchen; Yu, Jianfeng; Lee, L. James; Yi, Allen Y.
2018-07-01
Silicon is a promising mold material for compression molding because of its properties of hardness and abrasion resistance. Silicon wafers with carbide-bonded graphene coating and micro-patterns were evaluated as molds for the fabrication of microlens arrays. This study presents an efficient but flexible manufacturing method for microlens arrays that combines a lapping method and a rapid molding procedure. Unlike conventional processes for microstructures on silicon wafers, such as diamond machining and photolithography, this research demonstrates a unique approach by employing precision steel balls and diamond slurries to create microlenses with accurate geometry. The feasibility of this method was demonstrated by the fabrication of several microlens arrays with different aperture sizes and pitches on silicon molds. The geometrical accuracy and surface roughness of the microlens arrays were measured using an optical profiler. The measurement results indicated good agreement with the optical profile of the design. The silicon molds were then used to copy the microstructures onto polymer substrates. The uniformity and quality of the samples molded through rapid surface molding were also assessed and statistically quantified. To further evaluate the optical functionality of the molded microlens arrays, the focal lengths of the microlens arrays were measured using a simple optical setup. The measurements showed that the microlens arrays molded in this research were compatible with conventional manufacturing methods. This research demonstrated an alternative low-cost and efficient method for microstructure fabrication on silicon wafers, together with the follow-up optical molding processes.
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Transfer molding of PMR-15 polyimide resin
NASA Technical Reports Server (NTRS)
Reardon, J. P.; Moyer, D. W.; Nowak, B. E.
1985-01-01
Transfer molding is an economically viable method of producing small shapes of PMR-15 polyimide. It is shown that with regard to flexural, compressive, and tribological properties transfer-molded PMR-15 polyimide is essentially equivalent to PMR-15 polyimide produced by the more common method of compression molding. Minor variations in anisotropy are predictable effects of molding design and secondary finishing operations.
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Visualization analysis of tiger-striped flow mark generation phenomena in injection molding
NASA Astrophysics Data System (ADS)
Owada, Shigeru; Yokoi, Hidetoshi
2016-03-01
The generation mechanism of tiger-striped flow marks of polypropylene (PP)/rubber/talc blends in injection molding was investigated by dynamic visualization analysis in a glass-inserted mold. The analysis revealed that the behavior of the melt flow front correlates with the flow mark generation. The cloudy part in the tiger-striped flow marks corresponded to the low transcription rate area of the melt diverging near the cavity wall, while the glossy part corresponded to the high transcription rate area of the melt converging toward the cavity wall side. The melt temperature at the high transcription rate area was slightly lower than that at the low transcription rate area. These phenomena resulted due to the difference in the temperature of the melt front that was caused by the asymmetric fountain flow. These results suggest the followings; At the moment when the melt is broken near the one side of cavity wall due to piling the extensional strains up to a certain level, the melt spurts out near the broken side. It results in generating asymmetric fountain flow temporarily to relax the extensional front surface, which moves toward the opposite side to form the high transcription area.
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Simulation on Effect of Preform Diameter in Injection Stretch Blow Molding
NASA Astrophysics Data System (ADS)
Tan, Z. Q.; Rosli, Nurrina; Oktaviandri, Muchamad
2018-03-01
Polyethylene terephthalate (PET) is the most common material of resin for manufacturing plastic bottle by injection stretch blow molding due to its excellent properties. As various issues of health and environmental hazards due to the PET use have risen, PET bottle manufacture may be improved by minimizing the wall thickness to reduce the PET use. One of the critical qualifications of the manufacturing process which lead to the wall thickness distribution is the initial preform diameter. In this project, we used the ANSYS Polyflow with aim to evaluate the wall thickness distribution of PET bottle for different diameter of initial preform. As a result, only 4 mm preform diameter presented wall thickness below than 1 mm. On the other hand, at least 6 mm preform diameter can permit the wall thickness 1.3 mm i.e. at the shoulder area.
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NASA Astrophysics Data System (ADS)
Albert, Benedikt; Völkl, Rainer; Glatzel, Uwe
2014-09-01
For different high-temperature applications like aero engines or turbochargers, metal injection molding (MIM) of superalloys is an interesting processing alternative. For operation at high temperatures, oxidation behavior of superalloys produced by MIM needs to match the standard of cast or forged material. The oxidation behavior of nickel-based superalloys Inconel 713 and MAR-M247 in the temperature interval from 1073 K to 1373 K (800 °C to 1100 °C) is investigated and compared to cast material. Weight gain is measured discontinuously at different oxidation temperatures and times. Analysis of oxidized samples is done via SEM and EDX-measurements. MIM samples exhibit homogeneous oxide layers with a thickness up to 4 µm. After processing by MIM, Inconel 713 exhibits lower weight gain and thinner oxide layers than MAR-M247.
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Claeys, Bart; Vervaeck, Anouk; Vervaet, Chris; Remon, Jean Paul; Hoogenboom, Richard; De Geest, Bruno G
2012-10-15
Here we evaluate poly(2-ethyl-2-oxazoline)s (PEtOx) as a matrix excipient for the production of oral solid dosage forms by hot melt extrusion (HME) followed by injection molding (IM). Using metoprolol tartrate as a good water-soluble model drug we demonstrate that drug release can be delayed by HME/IM, with the release rate controlled by the molecular weight of the PEtOx. Using fenofibrate as a lipophilic model drug we demonstrate that relative to the pure drug the dissolution rate is strongly enhanced by formulation in HME/IM tablets. For both drug molecules we find that solid solutions, i.e. molecularly dissolved drug in a polymeric matrix, are obtained by HME/IM. Copyright © 2012 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.
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Improved silicon nitride for advanced heat engines
NASA Technical Reports Server (NTRS)
Yeh, Harry C.; Fang, Ho T.
1991-01-01
The results of a four year program to improve the strength and reliability of injection-molded silicon nitride are summarized. Statistically designed processing experiments were performed to identify and optimize critical processing parameters and compositions. Process improvements were monitored by strength testing at room and elevated temperatures, and microstructural characterization by optical, scanning electron microscopes, and scanning transmission electron microscope. Processing modifications resulted in a 20 percent strength and 72 percent Weibull slope improvement of the baseline material. Additional sintering aids screening and optimization experiments succeeded in developing a new composition (GN-10) capable of 581.2 MPa at 1399 C. A SiC whisker toughened composite using this material as a matrix achieved a room temperature toughness of 6.9 MPa m(exp .5) by the Chevron notched bar technique. Exploratory experiments were conducted on injection molding of turbocharger rotors.
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Lee, Jai-Sung; Choi, Joon-Phil; Lee, Geon-Yong
2013-01-01
This paper provides an overview on our recent investigations on the consolidation of hierarchy-structured nanopowder agglomerates and related applications to net-shaping nanopowder materials. Understanding the nanopowder agglomerate sintering (NAS) process is essential to processing of net-shaped nanopowder materials and components with small and complex shape. The key concept of the NAS process is to enhance material transport through controlling the powder interface volume of nanopowder agglomerates. Based upon this concept, we have suggested a new idea of full density processing for fabricating micro-powder injection molded part using metal nanopowder agglomerates produced by hydrogen reduction of metal oxide powders. Studies on the full density sintering of die compacted- and powder injection molded iron base nano-agglomerate powders are introduced and discussed in terms of densification process and microstructure. PMID:28788317
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Analysis of roll-stamped light guide plate fabricated with laser-ablated stamper
NASA Astrophysics Data System (ADS)
Na, Hyunjun; Hong, Seokkwan; Kim, Jongsun; Hwang, Jeongho; Joo, Byungyun; Yoon, Kyunghwan; Kang, Jeongjin
2017-12-01
LGP (light guide plate) is one of the major components of LCD (liquid crystal display), and it makes surface illumination for LCD backlit. LGP is a transparent plastic plate usually produced by injection molding process. On the back of LGP there are micron size patterns for extraction of light. Recently a roll-stamping process has achieved the high mass productivity of thinner LGPs. In order to fabricate optical patterns on LGPs, a fabricating tool called as a stamper is used. Micro patterns on metallic stampers are made by several micro machining processes such as chemical etching, LIGA-reflow, and laser ablation. In this study, a roll-stamping process by using a laser ablated metallic stamper was dealt with in consideration of the compatibility with the roll-stamping process. LGP fabricating tests were performed using a roll-stamping process with four different roll pressures. Pattern shapes on the stamper fabricated by laser ablation and transcription ratios of the roll-stamping process were analyzed, and LGP luminance was evaluated. Based on the evaluation, optical simulation model for LGP was made and simulation accuracy was evaluated. Simulation results showed good agreements with optical performance of LGPs in the brightness and uniformity. It was also shown that the roll-stamped LGP has the possibility of better optical performance than the conventional injection molded LGP. It was also shown that the roll-stamped LGP with the laser ablated stamper is potential to have better optical performance than the conventional injection molded LGP.
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The Influence of Injection Molding Parameter on Properties of Thermally Conductive Plastic
NASA Astrophysics Data System (ADS)
Hafizah Azis, N.; Zulafif Rahim, M.; Sa'ude, Nasuha; Rafai, N.; Yusof, M. S.; Tobi, ALM; Sharif, ZM; Rasidi Ibrahim, M.; Ismail, A. E.
2017-05-01
Thermally conductive plastic is the composite between metal-plastic material that is becoming popular because if it special characteristic. Injection moulding was regarded as the best process for mass manufacturing of the plastic composite due to its low production cost. The objective of this research is to find the best combination of the injection parameter setting and to find the most significant factor that effect the strength and thermal conductivity of the composite. Several parameter such as the volume percentage of copper powder, nozzle temperature and injection pressure of injection moulding machine were investigated. The analysis was done using Design Expert Software by implementing design of experiment method. From the analysis, the significant effects were determined and mathematical models of only significant effect were established. In order to ensure the validity of the model, confirmation run was done and percentage errors were calculated. It was found that the best combination parameter setting to maximize the value of tensile strength is volume percentage of copper powder of 3.00%, the nozzle temperature of 195°C and the injection pressure of 65%, and the best combination parameter settings to maximize the value of thermal conductivity is volume percentage of copper powder of 7.00%, the nozzle temperature of 195°C and the injection pressure of 65% as recommended..
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NASA Technical Reports Server (NTRS)
Eyre, Francis B. (Inventor); Fink, Wolfgang (Inventor)
2011-01-01
Disclosed herein is a method of making a three dimensional mold comprising the steps of providing a mold substrate; exposing the substrate with an electromagnetic radiation source for a period of time sufficient to render the portion of the mold substrate susceptible to a developer to produce a modified mold substrate; and developing the modified mold with one or more developing reagents to remove the portion of the mold substrate rendered susceptible to the developer from the mold substrate, to produce the mold having a desired mold shape, wherein the electromagnetic radiation source has a fixed position, and wherein during the exposing step, the mold substrate is manipulated according to a manipulation algorithm in one or more dimensions relative to the electromagnetic radiation source; and wherein the manipulation algorithm is determined using stochastic optimization computations.
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Optimization and evaluation of metal injection molding by using X-ray tomography
DOE Office of Scientific and Technical Information (OSTI.GOV)
Yang, Shidi; Zhang, Ruijie; Qu, Xuanhui, E-mail: quxh@ustb.edu.cn
2015-06-15
6061 aluminum alloy and 316L stainless steel green bodies were obtained by using different injection parameters (injection pressure, speed and temperature). After injection process, the green bodies were scanned by X-ray tomography. The projection and reconstruction images show the different kinds of defects obtained by the improper injection parameters. Then, 3D rendering of the Al alloy green bodies was used to demonstrate the spatial morphology characteristics of the serious defects. Based on the scanned and calculated results, it is convenient to obtain the proper injection parameters for the Al alloy. Then, reasons of the defect formation were discussed. During moldmore » filling, the serious defects mainly formed in the case of low injection temperature and high injection speed. According to the gray value distribution of projection image, a threshold gray value was obtained to evaluate whether the quality of green body can meet the desired standard. The proper injection parameters of 316L stainless steel can be obtained efficiently by using the method of analyzing the Al alloy injection. - Highlights: • Different types of defects in green bodies were scanned by using X-ray tomography. • Reasons of the defect formation were discussed. • Optimization of the injection parameters can be simplified greatly by the way of X-ray tomography. • Evaluation standard of the injection process can be obtained by using the gray value distribution of projection image.« less
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Pan, Jialiang; Hu, Yuling; Liang, Tingan; Li, Gongke
2012-11-02
A novel and simple in-mold coating strategy was proposed for the preparation of uniform solid-phase microextraction (SPME) coatings. Such a strategy is based on the direct synthesis of the polymer coating on the surface of a solid fiber using a glass capillary as the mold. The capillary was removed and the polymer with well-controlled thickness could be coated on the silica fiber reproductively. Following the strategy, a new poly(acrylamide-co-ethylene glycol dimethacrylate) (poly(AM-co-EGDMA)) coating was prepared for the preconcentration of 24-epibrassinolide (24-epiBL) from plant matrix. The coating had the enrichment factor of 32 folds, and the extraction efficiency per unit thickness was 5 times higher than that of the commercial polydimethylsiloxane/divinylbenzene (PDMS/DVB) coating. A novel method based on SPME coupled with derivatization and large volume injection-high performance liquid chromatography (LVI-HPLC) was developed for the analysis of 24-epiBL. The linear range was 0.500-20.0 μg/L with the detection limit of 0.13 μg/L. The amounts of endogenous 24-epiBL in rape and sunflower breaking-wall pollens samples were determined with satisfactory recovery (77.8-104%) and reproducibility (3.9-7.9%). The SPME-DE/LVI-HPLC method is rapid, reliable, convenient and applicable for complicated plant samples. Copyright © 2012 Elsevier B.V. All rights reserved.
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Incipient flocculation molding: A new ceramic-forming technique
NASA Astrophysics Data System (ADS)
Arrasmith, Steven Reade
Incipient Flocculation Molding (IFM) was conceived as a new near-net-shape forming technique for ceramic components. It was hypothesized that the development of a temperature-dependent deflocculant would result in a forming technique that is flexible, efficient, and capable of producing a superior microstructure with improved mechanical properties from highly reactive, submicron ceramic powders. IFM utilizes a concentrated, nonaqueous, sterically stabilized ceramic powder and/or colloidal suspension which is injected into a non-porous mold. The suspension is then flocculated by destabilizing the suspension by lowering the temperature. Flocculation is both rapid and reversible. Cooling to -20°C produces a green body with sufficient strength for removal from the mold. The solvent is removed from the green body by evaporation. The dried green body is subsequently sintered to form a dense ceramic monolith. This is the first ceramic forming method based upon the manipulation of a sterically-stabilized suspension. To demonstrate IFM, the process of grafting polyethylene glycol (PEG), with molecular weights from 600 to 8000, to alumina powders was investigated. The maximum grafted amounts were achieved by the technique of dispersing the alumina powders in molten polymer at 195°C. The ungrafted PEG was then removed by repeated centrifuging and redispersion in fresh distilled water. The rheological behavior of suspensions of the PEG-grafted powders in water, 2-propanol and 2-butanol were characterized. All of the aqueous suspensions were shear thinning. The PEG 4600-grafted alumina powder aqueous suspensions were the most fluid. Sample rods and bars were molded from 52 vol% PEG-grafted alumina suspensions in 2-butanol. The best results were obtained with a preheated aluminum mold lubricated with a fluorinated oil mold-release. The samples were dried, sintered, and their microstructure and density were compared with sintered samples dry pressed from the same alumina powder. Densities and microstructures were quite similar to those obtained by dry pressing and sintering these powders. Dried green samples with densities of ca. 57% of theoretical sintered to >96% of theoretical density. This research has demonstrated IFM as a viable ceramic forming process which has potential to be developed into an industrial process. Further research is needed to determine preferred molding parameters, other possible polymer-solvent systems, and investigate the use of other ceramic powders. The concepts developed for IFM may have potential applications in other ceramic forming processes, such as extrusion and rapid prototyping.
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Improved compression molding process
NASA Technical Reports Server (NTRS)
Heier, W. C.
1967-01-01
Modified compression molding process produces plastic molding compounds that are strong, homogeneous, free of residual stresses, and have improved ablative characteristics. The conventional method is modified by applying a vacuum to the mold during the molding cycle, using a volatile sink, and exercising precise control of the mold closure limits.
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3D Molding of Veneers by Mechanical and Pneumatic Methods
Gaff, Milan; Gašparík, Miroslav
2017-01-01
This paper deals with the influence of selected methods (mechanical and pneumatic) as well as various factors (wood species, moisture content, veneer shape, punch diameter, laminating foil thickness, holding method, plasticizing) on 3D molding of veneers. 3D molding was evaluated on the basis of maximum deflection of birch and beech veneers. Cracks and warping edges were also evaluated in selected groups of mechanical molding. Mechanical methods tested veneers with various treatments (steaming, water and ammonia plasticizing and lamination). The pneumatic method was based on veneer shaping using air pressure. The results indicate that birch veneers are more suitable for 3D molding. The differences between the mechanical and pneumatic methods were not considerable. The most suitable method for mechanical 3D molding was the veneer lamination by polyethylene foils with thicknesses of 80 and 125 μm, inasmuch as these achieved better results than veneer plasticized by steam. The occurrence of cracks was more frequent in beech veneers, whereas, edge warping occurred at similar rates for both wood species and depends rather on holding method during 3D molding. Use of the ammonia solution is more suitable and there occurs no marked increase in moisture as happens when soaking in water. PMID:28772684
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A Single Molecular Diels-Alder Crosslinker for Achieving Recyclable Cross-Linked Polymers.
Chen, Shengli; Wang, Fenfen; Peng, Yongjin; Chen, Tiehong; Wu, Qiang; Sun, Pingchuan
2015-09-01
A triol-functional crosslinker combining the thermoreversible properties of Diels-Alder (DA) adducts in one molecule is designed, synthesized, and used as an ideal substitute of a traditional crosslinker to prepare thermal recyclable cross-linked polyurethanes with excellent mechanical properties and recyclability in a very simple and efficient way. The recycle property of these materials achieved by the DA/retro-DA reaction at a suitable temperature is verified by differential scanning calorimetry and in situ variable temperature solid-state NMR experiments during the cyclic heating and cooling processes. The thermal recyclability and remending ability of the bulk polyurethanes is demonstrated by three polymer processing methods, including hot-press molding, injection molding, and solution casting. It is notable that all the recycled cross-linked polymers display nearly invariable elongation/stress at break compared to the as-synthesized samples. Further end-group functionalization of this single molecular DA crosslinker provides the potential in preparing a wide range of recyclable cross-linked polymers. © 2015 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.
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Ebaugh, Larry R.; Sadler, Collin P.; Carter, Gary D.
1992-01-01
An improved fin stabilized projectile including multiple stabilizer fins upon a stabilizer unit situated at the aft end of the projectile is provided, the improvement wherein the stabilizer fins are joined into the stabillizer unit by an injection molded engineering grade polymer.
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NASA Astrophysics Data System (ADS)
Fischer, Ulrich H. P.; Höll, Sebastian; Haupt, Matthias; Joncic, Mladen
2015-10-01
Polymer optical fibers (POF) offer only transmission so far with one wavelength at 650 nm. In order to increase the overall transfer rate, the key element for wavelength division multiplexing (WDM) over POF will be presented. This element is a demultiplexer (DEMUX), which was designed in polymethylmethacrylate with an optical grating on an aspherical mirror to be produced by injection molding in a further development steps. The master was produced by diamond turning as a master for injection molding replication. The results of the different simulations followed by the development steps and the measurements of the prototype are presented. This prototype is used as a DEMUX in a WDM system with four wavelengths. In the WDM system, bit-error ratio (BER) measurements with an 8.26 Gb/s cumulated data rate in an offline processed discrete multitone modulation technique have been achieved over 100 m SI-POF at a BER of 10-3.
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Study of soft magnetic iron cobalt based alloys processed by powder injection molding
NASA Astrophysics Data System (ADS)
Silva, Aline; Lozano, Jaime A.; Machado, Ricardo; Escobar, Jairo A.; Wendhausen, Paulo A. P.
As a near net shape process, powder injection molding (PIM) opens new possibilities to process Fe-Co alloys for magnetic applications. Due to the fact that PIM does not involve plastic deformation of the material during processing, we envisioned the possibility of eliminating vanadium (V), which is generally added to Fe-Co alloys to improve the ductility in order to enable its further shaping by conventional processes such as forging and cold rolling. In our investigation we have found out two main futures related to the elimination of V, which lead to a cost-benefit gain in manufacturing small magnetic components where high-saturation induction is needed at low frequencies. Firstly, the elimination of V enables the achievement of much better magnetic properties when alloys are processed by PIM. Secondly, a lower sintering temperature can be used when the alloy is processed starting with elemental Fe and Co powders without the addition of V.
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Bimodal metal micro-nanopowders for powder injection molding
NASA Astrophysics Data System (ADS)
Pervikov, Aleksandr; Rodkevich, Nikolay; Glazkova, Elena; Lerner, Marat
2017-12-01
The paper studies a bimodal metal powder composition designed to prepare feedstock for powder injection molding, as well as microstructure and porosity of sintered pats. Two kinds of metal powder compositions are used, in particular, a mixture of micro- and nanopowders and a bimodal powder prepared with dispersion of steel wire. The feedstock is prepared by mixing a bimodal metal powder composition with acetylacetone and paraffin wax. The microstructure of the debound parts is observed by scanning electron microscopy. The sintered parts are characterized by density measurements and metallographic analysis. The technique of the metal powder composition proves to affect the characteristics of sintered parts. Nanoparticles are shown in the interstitial spaces among the microparticles upon mixing micro- and nanopowders, but the regular distribution of nanoparticles on the surface of microparticles is observed in the bimodal powder providing the reduction of the porosity of sintered parts and increasing the density to the proper density of steel.
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DOE Office of Scientific and Technical Information (OSTI.GOV)
Sanadi, A.R.; Caulfield, D.F.; Jacobson, R.E.
Kenaf (Hibiscus Cannabinus) is a fast growing annual growth plant that is harvested for its bast fibers. These fibers have excellent specific properties and have potential to be outstanding reinforcing fillers in plastics. In our experiments, the fibers and polypropylene (PP) were blended in a thermokinetic mixer and then injection molded, with the fiber weight fractions varying to 60%. A maleated polypropylene was used to improve the interaction and adhesion between the non-polar matrix and the polar lignocellulosic fibers. The specific tensile and flexural moduli of a 50 % by volume (39 % by volume) of kenaf-PP composites compares favorablymore » with a 40 % by weight of glass fiber-PP injection molded composites, These results suggest that kenaf fibers are a viable alternative to inorganic/mineral based reinforcing fibers as long as the right processing conditions are used and for applications where the higher water absorption is not critical.« less
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DOE Office of Scientific and Technical Information (OSTI.GOV)
Sanadi, A.R.; Caulfield, D.F.; Jacobson, R.E.
Kenaf (Hibiscus cannabinus) is a fast growing annual growth plant that is harvested for its bast fibers. These fibers have excellent specific properties and have potential to be outstanding reinforcing fillers in plastics. In these experiments, the fibers and polypropylene (PP) were blended in a thermokinetic mixer and then injection molded, with the fiber weight fractions varying to 60%. A maleated polypropylene was used to improve the interaction and adhesion between the nonpolar matrix and the polar lignocellulosic fibers. The specific tensile and flexural moduli of a 50% by weight (39% by volume) of kenaf-PP composite compare favorably with amore » 40% by weight of glass fiber-PP injection-molded composite. These results suggest that kenaf fibers are a viable alternative to inorganic/mineral-based reinforcing fibers as long as the right processing conditions are used and they are used in applications where the higher water absorption is not critical.« less
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Microstructures and mechanical properties of powder injection molded Ti-6Al-4V/HA powder.
Thian, E S; Loh, N H; Khor, K A; Tor, S B
2002-07-01
Taguchi method with an L9 orthogonal array was employed to investigate the sintered properties of Ti-6Al-4V/HA tensile bars produced by powder injection molding. The effects of sintering factors at the 90% significance level: sintering temperature (1050 degrees C, 1100 degrees C and 1150 degrees C), heating rate (5 degrees C/min, 7.5 degrees C/min and 10 degrees C/min), holding time (30, 45 and 60 min) and cooling rate (5 degrees C/min, 20 degrees C/min and 40 degrees C/min) were investigated. Results showed that sintering temperature, heating rate and cooling rate have significant effects on sintered properties, whereas the influence of holding time was insignificant. It was found that a sintering temperature of 1100 degrees C, a heating rate of 7.5 degrees C/min and a cooling rate of 5 degrees C/min increased the relative density, Vicker's microhardness, flexural strength and flexural modulus. However, a further increment of sintering temperature to 1150 degrees C did not show any discernable improvement in the relative density and Vicker's microhardness, but there was a slight increase of 0.6% and 0.9% in the flexural strength and flexural modulus, respectively. Mechanically strong Ti-6Al-4V/HA parts with an open porosity of around 50% were developed.
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Morphological studies on block copolymer modified PA 6 blends
DOE Office of Scientific and Technical Information (OSTI.GOV)
Poindl, M., E-mail: marcus.poindl@ikt.uni-stuttgart.de, E-mail: christian.bonten@ikt.uni-stuttgart.de; Bonten, C., E-mail: marcus.poindl@ikt.uni-stuttgart.de, E-mail: christian.bonten@ikt.uni-stuttgart.de
Recent studies show that compounding polyamide 6 (PA 6) with a PA 6 polyether block copolymers made by reaction injection molding (RIM) or continuous anionic polymerization in a reactive extrusion process (REX) result in blends with high impact strength and high stiffness compared to conventional rubber blends. In this paper, different high impact PA 6 blends were prepared using a twin screw extruder. The different impact modifiers were an ethylene propylene copolymer, a PA PA 6 polyether block copolymer made by reaction injection molding and one made by reactive extrusion. To ensure good particle matrix bonding, the ethylene propylene copolymermore » was grafted with maleic anhydride (EPR-g-MA). Due to the molecular structure of the two block copolymers, a coupling agent was not necessary. The block copolymers are semi-crystalline and partially cross-linked in contrast to commonly used amorphous rubbers which are usually uncured. The combination of different analysis methods like atomic force microscopy (AFM), transmission electron microscopy (TEM) and scanning electron microscopy (SEM) gave a detailed view in the structure of the blends. Due to the partial cross-linking, the particles of the block copolymers in the blends are not spherical like the ones of ethylene propylene copolymer. The differences in molecular structure, miscibility and grafting of the impact modifiers result in different mechanical properties and different blend morphologies.« less
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Hafeman, Andrea E.; Li, Bing; Yoshii, Toshitaka; Zienkiewicz, Katarzyna; Davidson, Jeffrey M.; Guelcher, Scott A.
2013-01-01
Purpose The purpose of this work was to investigate the effects of triisocyanate composition on the biological and mechanical properties of biodegradable, injectable polyurethane scaffolds for bone and soft tissue engineering. Methods Scaffolds were synthesized using reactive liquid molding techniques, and were characterized in vivo in a rat subcutaneous model. Porosity, dynamic mechanical properties, degradation rate, and release of growth factors were also measured. Results Polyurethane scaffolds were elastomers with tunable damping properties and degradation rates, and they supported cellular infiltration and generation of new tissue. The scaffolds showed a two-stage release profile of platelet-derived growth factor, characterized by a 75% burst release within the first 24 h and slower release thereafter. Conclusions Biodegradable polyurethanes synthesized from triisocyanates exhibited tunable and superior mechanical properties compared to materials synthesized from lysine diisocyanates. Due to their injectability, biocompatibility, tunable degradation, and potential for release of growth factors, these materials are potentially promising therapies for tissue engineering. PMID:18516665
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METHOD FOR EVALUATING MOLD GROWTH ON CEILING TILE
A method to extract mold spores from porous ceiling tiles was developed using a masticator blender. Ceiling tiles were inoculated and analyzed using four species of mold. Statistical analysis comparing results obtained by masticator extraction and the swab method was performed. T...
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Improved Sand-Compaction Method for Lost-Foam Metal Casting
NASA Technical Reports Server (NTRS)
Bakhtiyarov, Sayavur I.; Overfelt, Ruel A.
2008-01-01
An improved method of filling a molding flask with sand and compacting the sand around a refractory-coated foam mold pattern has been developed for incorporation into the lost-foam metal-casting process. In comparison with the conventional method of sand filling and compaction, this method affords more nearly complete filling of the space around the refractory-coated foam mold pattern and more thorough compaction of the sand. In so doing, this method enables the sand to better support the refractory coat under metallostatic pressure during filling of the mold with molten metal.
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A new method of fabricating a blend scaffold using an indirect three-dimensional printing technique.
Jung, Jin Woo; Lee, Hyungseok; Hong, Jung Min; Park, Jeong Hun; Shim, Jung Hee; Choi, Tae Hyun; Cho, Dong-Woo
2015-11-03
Due to its simplicity and effectiveness, the physical blending of polymers is considered to be a practical strategy for developing a versatile scaffold having desirable mechanical and biochemical properties. In the present work, an indirect three-dimensional (i3D) printing technique was proposed to fabricate a 3D free-form scaffold using a blend of immiscible materials, such as polycaprolactone (PCL) and gelatin. The i3D printing technique includes 3D printing of a mold and a sacrificial molding process. PCL/chloroform and gelatin/water were physically mixed to prepare the blend solution, which was subsequently injected into the cavity of a 3D printed mold. After solvent removal and gelatin cross-linking, the mold was dissolved to obtain a PCL-gelatin (PG) scaffold, with a specific 3D structure. Scanning electron microscopy and Fourier transform infrared spectroscopy analysis indicated that PCL masses and gelatin fibers in the PG scaffold homogenously coexisted without chemical bonding. Compression tests confirmed that gelatin incorporation into the PCL enhanced its mechanical flexibility and softness, to the point of being suitable for soft-tissue engineering, as opposed to pure PCL. Human adipose-derived stem cells, cultured on a PG scaffold, exhibited enhanced in vitro chondrogenic differentiation and tissue formation, compared with those on a PCL scaffold. The i3D printing technique can be used to blend a variety of materials, facilitating 3D scaffold fabrication for specific tissue regeneration. Furthermore, this convenient and versatile technique may lead to wider application of 3D printing in tissue engineering.
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Conductivity fuel cell collector plate and method of fabrication
Braun, James C.
2002-01-01
An improved method of manufacturing a PEM fuel cell collector plate is disclosed. During molding a highly conductive polymer composite is formed having a relatively high polymer concentration along its external surfaces. After molding the polymer rich layer is removed from the land areas by machining, grinding or similar process. This layer removal results in increased overall conductivity of the molded collector plate. The polymer rich surface remains in the collector plate channels, providing increased mechanical strength and other benefits to the channels. The improved method also permits greater mold cavity thickness providing a number of advantages during the molding process.
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EPA Scientists Develop Research Methods for Studying Mold Fact Sheet
In 2002, U.S. Environmental Protection Agency researchers developed a DNA-based Mold Specific Quantitative Polymerase Chain Reaction method (MSQPCR) for identifying and quantifying over 100 common molds and fungi.
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Cicala, Gianluca; Latteri, Alberta; Del Curto, Barbara; Lo Russo, Alessio; Recca, Giuseppe; Farè, Silvia
2017-01-28
Among additive manufacturing techniques, the filament-based technique involves what is referred to as fused deposition modeling (FDM). FDM materials are currently limited to a selected number of polymers. The present study focused on investigating the potential of using high-end engineering polymers in FDM. In addition, a critical review of the materials available on the market compared with those studied here was completed. Different engineering thermoplastics, ranging from industrial grade polycarbonates to novel polyetheretherketones (PEEKs), were processed by FDM. Prior to this, for innovative filaments based on PEEK, extrusion processing was carried out. Mechanical properties (i.e., tensile and flexural) were investigated for each extruded material. An industrial-type FDM machine (Stratasys Fortus® 400 mc) was used to fully characterize the effect of printing parameters on the mechanical properties of polycarbonate. The obtained properties were compared with samples obtained by injection molding. Finally, FDM samples made of PEEK were also characterized and compared with those obtained by injection molding. The effect of raster to raster air gap and raster angle on tensile and flexural properties of printed PC was evidenced; the potential of PEEK filaments, as novel FDM material, was highlighted in comparison to state of the art materials. Comparison with injection molded parts allowed to better understand FDM potential for functional applications. The study discussed pros and cons of the different materials. Finally, the development of novel PEEK filaments achieved important results offering a novel solution to the market when high mechanical and thermal properties are required.
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NASA Astrophysics Data System (ADS)
Zaidi, N. A.; Rosli, Muhamad Farizuan; Effendi, M. S. M.; Abdullah, Mohamad Hariri
2017-09-01
For almost all injection molding applications of Polyethylene Terephthalate (PET) plastic was analyzed the strength, durability and stiffness of properties by using Finite Element Method (FEM) for jointing system of wood furniture. The FEM was utilized for analyzing the PET jointing system for Oak and Pine as wood based material of furniture. The difference pattern design of PET as wood jointing furniture gives the difference value of strength furniture itself. The results show the wood specimen with grooves and eclipse pattern design PET jointing give lower global estimated error is 28.90%, compare to the rectangular and non-grooves wood specimen of global estimated error is 63.21%.
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Ceramic technology for solar thermal receivers
NASA Technical Reports Server (NTRS)
Kudirka, A. A.; Smoak, R. H.
1981-01-01
The high-temperature capability, resistance to corrosive environments and non-strategic nature of ceramics have prompted applications in the solar thermal field whose advantages over metallic devices of comparable performance may begin to be assessed. It is shown by a survey of point-focusing receiver designs employing a variety of ceramic compositions and fabrication methods that the state-of-the-art in structural ceramics is not sufficiently advanced to fully realize the promised benefits of higher temperature capabilities at lower cost than metallic alternatives. The ceramics considered include alumina, berylia, magnesia, stabilized zirconia, fused silica, silicon nitride, silicon carbide, mullite and cordierite, processed by such methods as isostatic pressing, dry pressing, slip casting, extrusion, calendaring and injection molding.
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NASA Astrophysics Data System (ADS)
Yu, Yishan
The influence of various fillers, nucleating agents and ethylene propylene diene terpolymer (EPDM) additive on crystalline modification (alpha-, beta- and smectic forms) and crystalline orientation of polypropylene in die extrudates, melt spun filaments, thick rods, blow molded bottles and injection molded parts of isotactic polypropylene (PP), its blends/compounds and dynamically vulcanized polypropylene thermoplastic elastomers (TPEs) were experimentally studied under a range of cooling and processing conditions. The phenomena of crystallization, polymorphism and orientation in processing of both thin and thick samples (filaments, rods, bottles and injection molded parts) were simulated through transport laws incorporating polymer crystallization kinetics. Continuous cooling transformation (CCT) curves for the various material systems investigated were developed under quiescent and uniaxial stress conditions. We applied experimental data on polymorphism of thin sections to predict crystalline structure variation in thick parts. The predictions were consistent with experiments. For filaments, the polypropylene crystalline orientation-spinline stress relationship is generally similar for the neat PP, blends/compounds and TPEs. However, the blends and TPEs have much lower birefringence apparently due to a lack of orientation in the rubber phase. It was shown that the polypropylene contribution to the birefringence for the neat PP and its blends is the same at the same spinline stress. For bottles, the inflation pressures used have little effect on orientation of either polypropylene crystals or disc-shaped talc filler. The talc discs are highly oriented parallel to the bottle surface. For the bottles without talc, the orientation of polypropylene crystallographic axes are low. The polypropylene crystallographic b-axes in the talc filled bottles are more highly oriented. For injection molded parts, it was found that a low orientation layer exists between the part surface and an intermediate highly oriented layer in the parts of neat PP and its blends/compounds. The thickness of this layer increases as the injection pressure decreases. This layer was not formed in the TPE parts. This would seem to be associated with the TPEs exhibiting a yield stress in shear flow and not exhibiting fountain flow in mold filling. For all parts studied, the orientation characteristics of polypropylene crystallographic axes in the highly oriented layer are similar from sample to sample. The strong orientation of the c-axis parallel to the machine direction and the b-axis perpendicular to the machine direction are observed in the highly oriented layer. The talc discs in both the highly oriented layer and the intermediate position are highly oriented parallel to the part face due to melt flow. At intermediate position in the talc-filled parts, the polypropylene crystallographic (040) planes prefer to align themselves parallel to the part surface but are not so well oriented when the talc is absent.
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Sadeghi-Avalshahr, Ali Reza; Khorsand-Ghayeni, Mohammad; Nokhasteh, Samira; Molavi, Amir Mahdi; Sadeghi-Avalshahr, Mohammad
2016-12-01
The purpose of this study was to produce and evaluate different mechanical, physical and in vitro cell culture characteristics of poly(L-lactic) acid (PLLA) interference screws. This work will focus on evaluating the effect of two important parameters on operation of these screws, first the tunnel diameter which is one of the most important parameters during the operation and second the thermal behavior, the main effective characteristic in production process. In this work, PLLA screws were produced by a two-stage injection molding machine. For mechanical assessment of the produced screws, Polyurethane rigid foam was used as cancellous bone and polypropylene rope as synthetic graft to simulate bone and ligament in real situation. Different tunnel diameters including 7-10 mm were evaluated for fixation strength. When the tunnel diameter was changed from 10 to 9 mm, the pull-out force has increased to about 12 %, which is probably due to the aforementioned frictional forces, however, by reducing the tunnel diameter to 8 and 7 mm, the pull-out force reduced to 16 and 50 % for 8 and 7 mm tunnel diameter, respectively. The minimum and maximum pull-out force was obtained 160.57 and 506.86 N for 7 and 9 mm tunnel diameters, respectively. For physicochemical assay, Fourier transform infrared spectroscopy (FTIR), degradation test and differential scanning calorimetry (DSC) were carried out. The crystallinity (Xc) of samples were decreased considerably from 64.3 % before injection to 32.95 % after injection with two different crystallographic forms α' and α. probably due to the fast cooling rate at room temperature. In addition, MTT and cell attachment assays were utilized by MG63 osteoblast cell line, to evaluate the cytotoxicity of the produced screws. The results revealed no cytotoxicity effect.
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Mondrinos, Mark J; Dembzynski, Robert; Lu, Lin; Byrapogu, Venkata K C; Wootton, David M; Lelkes, Peter I; Zhou, Jack
2006-09-01
Drop on demand printing (DDP) is a solid freeform fabrication (SFF) technique capable of generating microscale physical features required for tissue engineering scaffolds. Here, we report results toward the development of a reproducible manufacturing process for tissue engineering scaffolds based on injectable porogens fabricated by DDP. Thermoplastic porogens were designed using Pro/Engineer and fabricated with a commercially available DDP machine. Scaffolds composed of either pure polycaprolactone (PCL) or homogeneous composites of PCL and calcium phosphate (CaP, 10% or 20% w/w) were subsequently fabricated by injection molding of molten polymer-ceramic composites, followed by porogen dissolution with ethanol. Scaffold pore sizes, as small as 200 microm, were attainable using the indirect (porogen-based) method. Scaffold structure and porosity were analyzed by scanning electron microscopy (SEM) and microcomputed tomography, respectively. We characterized the compressive strength of 90:10 and 80:20 PCL-CaP composite materials (19.5+/-1.4 and 24.8+/-1.3 Mpa, respectively) according to ASTM standards, as well as pure PCL scaffolds (2.77+/-0.26 MPa) fabricated using our process. Human embryonic palatal mesenchymal (HEPM) cells attached and proliferated on all scaffolds, as evidenced by fluorescent nuclear staining with Hoechst 33258 and the Alamar Blue assay, with increased proliferation observed on 80:20 PCL-CaP scaffolds. SEM revealed multilayer assembly of HEPM cells on 80:20 PCL-CaP composite, but not pure PCL, scaffolds. In summary, we have developed an SFF-based injection molding process for the fabrication of PCL and PCL-CaP scaffolds that display in vitro cytocompatibility and suitable mechanical properties for hard tissue repair.
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Design of permanent magnet synchronous motor speed control system based on SVPWM
NASA Astrophysics Data System (ADS)
Wu, Haibo
2017-04-01
The control system is designed to realize TMS320F28335 based on the permanent magnet synchronous motor speed control system, and put it to quoting all electric of injection molding machine. The system of the control method used SVPWM, through the sampling motor current and rotating transformer position information, realize speed, current double closed loop control. Through the TMS320F28335 hardware floating-point processing core, realize the application for permanent magnet synchronous motor in the floating point arithmetic, to replace the past fixed-point algorithm, and improve the efficiency of the code.
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Boonruksa, Pongsit; Bello, Dhimiter; Zhang, Jinde; Isaacs, Jacqueline A; Mead, Joey L; Woskie, Susan R
2016-01-01
Carbon nanotube (CNT) polymer composites are widely used as raw materials in multiple industries because of their excellent properties. This expansion, however, is accompanied by realistic concerns over potential release of CNTs and associated nanoparticles during the manufacturing, recycling, use, and disposal of CNT composite products. Such data continue to be limited, especially with regards to post-processing of CNT-enabled products, recycling and handling of nanowaste, and end-of-life disposal. This study investigated for the first time airborne nanoparticle and fibers exposures during injection molding and recycling of CNT polypropylene composites (CNT-PP) relative to that of PP. Exposure characterization focused on source emissions during loading, melting, molding, grinding, and recycling of scrap material over 20 cycles and included real-time characterization of total particle number concentration and size distribution, nanoparticle and fiber morphology, and fiber concentrations near the operator. Total airborne nanoparticle concentration emitted during loading, melting, molding, and grinding of CNT-PP had geometric mean ranging from 1.2 × 10(3) to 4.3 × 10(5) particles cm(-3), with the highest exposures being up to 2.9 and 300.7 times above the background for injection molding and grinding, respectively. Most of these emissions were similar to PP synthesis. Melting and molding of CNT-PP and PP produced exclusively nanoparticles. Grinding of CNT-PP but not PP generated larger particles with encapsulated CNTs, particles with CNT extrusions, and respirable fiber (up to 0.2 fibers cm(-3)). No free CNTs were found in any of the processes. The number of recycling runs had no significant impact on exposures. Further research into the chemical composition of the emitted nanoparticles is warranted. In the meanwhile, exposure controls should be instituted during processing and recycling of CNT-PP. © The Author 2015. Published by Oxford University Press on behalf of the British Occupational Hygiene Society.
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DRAPING SIMULATION OF WOVEN FABRICS
DOE Office of Scientific and Technical Information (OSTI.GOV)
Rodgers, William; Jin, Xiaoshi; Zhu, Jiang
2016-09-07
Woven fabric composites are extensively used in molding complex geometrical shapes due to their high conformability compared to other fabrics. Preforming is an important step in the overall process, where the two-dimensional fabric is draped to become the three-dimensional shape of the part prior to resin injection. During preforming, the orientation of the yarns may change significantly compared to the initial orientations. Accurate prediction of the yarn orientations after molding is important for evaluating the structural performance of the final part. This paper presents a systematic investigation of the angle changes during the preform operation for carbon fiber twill andmore » satin weave fabrics. Preforming experiments were conducted using a truncated pyramid mold geometry designed and fabricated at the General Motors Research Laboratories. Predicted results for the yarn orientations were compared with experimental results and good agreement was observed« less
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Pressurized Shell Molds For Metal-Matrix Composites
NASA Technical Reports Server (NTRS)
Kashalikar, Uday K.; Lusignea, Richard N.; Cornie, James
1993-01-01
Balanced-pressure molds used to make parts in complex shapes from fiber-reinforced metal-matrix composite materials. In single step, molding process makes parts in nearly final shapes; only minor finishing needed. Because molding pressure same on inside and outside, mold does not have to be especially strong and can be made of cheap, nonstructural material like glass or graphite. Fibers do not have to be cut to conform to molds. Method produces parts with high content of continuous fibers. Parts stiff but light in weight, and coefficients of thermal expansion adjusted. Parts resistant to mechanical and thermal fatigue superior to similar parts made by prior fabrication methods.
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Characterization of polymeric binders for Metal Injection Molding (MIM) process
NASA Astrophysics Data System (ADS)
Adames, Juan M.
The Metal Injection Molding (MIM) process is an economically attractive method of producing large amounts of small and complex metallic parts. This is achieved by combining the productivity of injection molding with the versatility of sintering of metal particulates. In MIM, the powdered metal is blended with a plastic binder to obtain the feedstock. The binder imparts flowability to the blend at injection molding conditions and strength at ambient conditions. After molding, the binder is removed in a sequence of steps that usually involves solvent-extraction and polymer burn-out. Once the binder is removed, the metal particles are sintered. In this research several topics of the MIM process were studied to understand how the polymeric binder, similar to the one used in the sponsoring company, works. This was done by examining the compounding and water debinding processes, the rheological and thermal properties, and the microstructure of the binder/metal composite at different processing stages. The factors studied included the metal contents, the composition of the binder and the processing conditions. The three binders prepared during the course of this research were blends of a polyolefin, polyoxymethylene copolymer (POM) and a water-soluble polymer (WSP). The polyolefin resins included polypropylene (PP), high-density polyethylene (HDPE) and linear low-density polyethylene (LLDPE). The powdered metal in the feedstocks was 316 L stainless steel. The compounding studies were completed in an internal mixer under different conditions of temperature, rotational speed and feedstock composition. It was found that the metal concentration was the most important factor in determining the torque evolution curves. The observation of microstructure with Scanning Electron Microscope (SEM) at different stages during compounding revealed that the metal particles neither agglomerate nor touch each other. The liquid extraction of the water-soluble polymer (WSP) from the molded parts (or water debinding) was investigated using two configurations of flow of water relative to the samples. Both permitted the reduction of the mass transfer resistance outside the parts, revealing information on the diffusion of the WSP inside the part exclusively. The debinding studies showed that a single effective diffusivity could be used to model the extraction process of the binder from molded parts. This approach is more accurate when the debinding time is above 2 hours. Steady shear and dynamic experiments were conducted on the binder and feedstocks samples containing LLDPE. The results of both experiments revealed that the feedstocks did not show yield stress even though the highest metal content was 64% by volume. Therefore, it was concluded that there were only hydrodynamic interactions between the metal particles. The thermal characterization of binders, polymers and feedstocks included differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA). The DSC tests were performed after preheating and quenching of the samples. The heating rate was 20°C/min. The TGA scans were conducted from room temperature to 700°C at 20°C/min. The DSC tests revealed that the melting point of the polymers depressed when blended in the binders and feedstocks. The depression was more intense for POM and the water-soluble polymer than for the polyolefins. Therefore, it was concluded that the melting point depression of POM and the water-soluble polymer was caused by their entrapment in the polyolefin matrix and in between the metal particles. The TGA scans showed that the feedstocks with higher metal concentration had higher final decomposition temperature, but similar onset temperature. The reason was that the higher the metal concentration the more difficult the diffusion of the products of the decomposition of the binder out of the samples. The morphological studies revealed that the binders were heterogeneous showing domains of the polar resins, embedded in a continuous phase composed of polyolefin. This distribution of phases was the result of the immiscibility between the polymeric components, and of the higher concentration (>70 vol%) of the polyolefin with respect to the polar components (polyoxymethylene and water-soluble polymer). The deformation during steady shear testing and compounding of the binder with the metal modified the size of the dispersed domains. The steady shearing increased the size of the dispersed domains by coalescence of the particles. On the other hand, the presence of powdered metal during compounding forced a redistribution of the dispersed phases. Apparently, a thin heterogeneous layer of binder surrounded the metal particles while most of the polyolefin occupied the space between the coated metal particles. The SEM study on samples obtained after water debinding revealed that the water-soluble polymer did not distribute uniformly on the surface of the molded disk of feedstock used for water debinding tests.
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Modeling and optimization of the hot embossing process for micro- and nanocomponent fabrication
NASA Astrophysics Data System (ADS)
Worgull, M.; Heckele, Mathias P.; Hétu, J. F.; Kabanemi, K. K.
2006-01-01
Hot embossing and injection molding belong to the established plastic molding processes in microengineering. Based on experimental findings, a variety of microstructures have been replicated using these processes. However, with increasing requirements regarding the embossing surface, and the simultaneous decrease of the structure size down into the nanorange, increasing know-how is needed to adapt hot embossing to industrial standards. To reach this objective, a German-Canadian cooperation project has been launched to study hot embossing theoretically by process simulation and experimentally. The present publication reports on the proceeding and present first results.
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Net shape fabrication of Alpha Silicon Carbide turbine components
NASA Technical Reports Server (NTRS)
Storm, R. S.
1982-01-01
Development of Alpha Silicon Carbide components by net shape fabrication techniques has continued in conjunction with several turbine engine programs. Progress in injection molding of simple parts has been extended to much larger components. Turbine rotors fabricated by a one piece molding have been successfully spin tested above design speeds. Static components weighing up to 4.5 kg and 33 cc in diameter have also been produced using this technique. Use of sintering fixtures significantly improves dimensional control. A new Si-SiC composite material has also been developed with average strengths up to 1000 MPa (150 ksi) at 1200 C.
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Development of Thixomolded{reg_sign} magnesium products
DOE Office of Scientific and Technical Information (OSTI.GOV)
Ghosh, D.; Fan, R.; Kang, K.
1995-10-01
Thixomolding{reg_sign} is a racial new process which merges the technologies of die-casting and plastic injection molding for the net shape molding of magnesium based alloys. Properties of Thixomolded{reg_sign} magnesium alloys are discussed and compared with those of traditional die casting. Magnesium alloys are of great interest to automobile manufacturers because of the potential weight savings and corresponding energy savings due to increased fuel economy. For this reason, one of the first target markets for Thixomolded{reg_sign} products is the automotive industry. The use of Thixomolding{reg_sign} in the production of an automobile part is examined.
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Design and fabrication of a multi-focusing artificial compound eyes with negative meniscus substrate
NASA Astrophysics Data System (ADS)
Luo, Jiasai; Guo, Yongcai; Wang, Xin; Fan, Fenglian
2017-04-01
Miniaturized artificial compound eyes with a large field of view (FOV) have potential application in the area of micro-optical-electro-mechanical-system (MOEMS). A new non-uniform microlens array (MLA) on a negative meniscus substrate, fabricated by the melting photoresist method, was proposed in this paper. The multi-focusing MLA reduced the defocus effectively, which was caused by the uniform array on a spherical substrate. Moreover, like most ommatidia in compound eyes, each microlens of the multi-focusing MLA was arranged in one of the eleven concentric circles. In order to match with the multi-focusing MLA and avoid the total reflection, the negative meniscus substrate was fabricated by a homebuilt mold with a micro-hole array and polydimethylsiloxane coelomic compartment attached. The coelomic compartment is capable of offering an excellent injection environment without bubbles and impurities. Due to the direct 3D implementation of the MLA, rich available materials can be used by this method without substrate reshaping. As the molding material, the ultraviolet curing adhesive NOA81 can be cured within ten few seconds under ultraviolet which relieve intensive labor and protect the stereolithography apparatus effectively. The experimental results show that this new MLA has a better imaging performance, higher light usage efficiency and larger FOV because of the negative meniscus and multi-focusing MLA. Moreover, due to the homebuilt mold, more accurate geometrical parameters and shorter processing cycle were realized. Accordingly, together with an appropriate hardware, this MLA has diverse potential applications in medical imaging, military and machine vision.
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NASA Astrophysics Data System (ADS)
Grujicic, M.; Sellappan, V.; He, T.; Seyr, Norbert; Obieglo, Andreas; Erdmann, Marc; Holzleitner, Jochen
2009-03-01
Over the last dozen of years, polymer metal hybrid (PMH) technologies have established themselves as viable alternatives for use in light-weight automotive body-in-white bolt-on as well as load-bearing (structural) components. Within the PMH technologies, sheet-metal stamped/formed and thermoplastic injection molding subcomponents are integrated into a singular component/module. Due to attending synergetic effects, the performance of the PMH component typically exceeds that attainable by an alternative single-material technologies. In the present work, a total life cycle (TLC) approach to the selection of metallic and thermoplastic materials (as well as the selection of structural adhesives, where appropriate) is considered. The TLC material selection approach considers the consequences and ramifications of material selection at each major stage of the vehicle manufacturing process chain (press shop, injection molding shop, body shop, paint shop, and assembly), as well as relation to the vehicle performance, durability and the end-of-the-life-of-the-vehicle considerations. The approach is next applied to the case of injection overmolding technology to identify the optimal grade of short glass-fiber reinforced nylon when used in a prototypical PMH load-bearing automotive body-in-white component.
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Effects of POE-g-MAH on properties of PP-based binder in metal injection molding
NASA Astrophysics Data System (ADS)
Li, Duxin; Zhang, Chenming; Ding, Chuxiong; Pan, Donghua; Lu, Renwei; Yang, Zhongchen
2018-06-01
The objective of this study is to explore the effects of maleic anhydride-grafted polyolefin elastomer (POE-g-MAH) on properties of polypropylene (PP)-based binder. The viscosity of feedstocks as well as properties of green parts, brown parts and sintered parts were investigated. Through the analysis of viscosity, the feedstock containing 8 vol% POE-g-MAH in binder was supposed to be more suitable for the injection molding. The impact absorbed energy at break increased with increasing POE-g-MAH content in binder while the bending strength decreased first and then increased. The introduction of POE-g-MAH improve the density distribution and increased the density of green parts. After debinding, most binder components were removed regardless of the POE-g-MAH content in binder. As for the parts after sintering, the carbon content decreased with an increase in POE-g-MAH content. The results suggest that POE-g-MAH act as a toughening agent as well as compatibilizer for PP-based binder/metal powder system. The mechanical properties of the green parts could be enhanced even after multiple injection and in addition the powder-binder separation trend could be decreased.
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Method and composition for molding low density desiccant syntactic foam articles
Lula, James W.; Schicker, James R.
1984-01-01
A method and a composition are provided for molding low density desiccant syntactic foam articles. A low density molded desiccant article may be made as a syntactic foam by blending a thermosetting resin, microspheres and molecular sieve desiccant powder, molding and curing. Such articles have densities of 0.2-0.9 g/cc, moisture capacities of 1-12% by weight, and can serve as light weight structural supports.
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Research on mechanical properties of carbon fiber /polyamide reinforced PP composites
NASA Astrophysics Data System (ADS)
Chen, Xinghui; Yu, Qiang; Liu, Lixia; Ji, Wenhua; Yang, Li; Fan, Dongli
2017-10-01
The polyamide composites reinforced by carbon fiber/polypropylene are produced by injection molding processing. The flow abilities and mechanical properties of the CF/PA/PP composite materials are studied by the fusion index instrument and the universal testing machine. The results show that with the content of carbon fiber/polyamide increase, the impact breaking strength and the tensile property of the composite materials increase, which is instructive to the actual injection production of polypropylene products.
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NASA Astrophysics Data System (ADS)
Moritzer, Elmar; Martin, Yannick
2016-03-01
The demand for materials based on renewable raw materials has risen steadily in recent years. With society's increasing interest for climate protection and sustainability, natural-based materials such as wood-plastic-composites (WPC) have gained market share thanks to their positive reputation. Due to advantages over unreinforced plastics such as cost reduction and weight savings it is possible to use WPC in a wide area of application. Additionally, an increase in mechanical properties such as rigidity and strength is achieved by the fibers compared to unreinforced polymers. The combination of plastic and wood combines the positive properties of both components in an innovative material. Despite the many positive properties of wood-plastic-composite, there are also negative characteristics that prevent the use of WPC in many product areas, such as automotive interiors. In particular, increased water intake, which may result in swelling of near-surface particles, increased odor emissions, poor surface textures and distortion of the components are unacceptable for many applications. The sandwich injection molding process can improve this situation by eliminating the negative properties of WPC by enclosing it with a pure polymer. In this case, a layered structure of skin and core material is produced, wherein the core component is completely enclosed by the skin component. The suitability of WPC as the core component in the sandwich injection molding has not yet been investigated. In this study the possibilities and limitations of the use of WPC are presented. The consideration of different fiber types, fiber contents, skin materials and its effect on the filling behavior are the focus of the presented analysis.
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Consumer electronic optics: how small can a lens be: the case of panomorph lenses
NASA Astrophysics Data System (ADS)
Thibault, Simon; Parent, Jocelyn; Zhang, Hu; Du, Xiaojun; Roulet, Patrice
2014-09-01
In 2014, miniature camera modules are applied to a variety of applications such as webcam, mobile phone, automotive, endoscope, tablets, portable computers and many other products. Mobile phone cameras are probably one of the most challenging parts due to the need for smaller and smaller total track length (TTL) and optimized embedded image processing algorithms. As the technology is developing, higher resolution and higher image quality, new capabilities are required to fulfil the market needs. Consequently, the lens system becomes more complex and requires more optical elements and/or new optical elements. What is the limit? How small an injection molded lens can be? We will discuss those questions by comparing two wide angle lenses for consumer electronic market. The first lens is a 6.56 mm (TTL) panoramic (180° FOV) lens built in 2012. The second is a more recent (2014) panoramic lens (180° FOV) with a TTL of 3.80 mm for mobile phone camera. Both optics are panomorph lenses used with megapixel sensors. Between 2012 and 2014, the development in design and plastic injection molding allowed a reduction of the TTL by more than 40%. This TTL reduction has been achieved by pushing the lens design to the extreme (edge/central air and material thicknesses as well as lens shape). This was also possible due to a better control of the injection molding process and material (low birefringence, haze and thermal stability). These aspects will be presented and discussed. During the next few years, we don't know if new material will come or new process but we will still need innovative people and industries to push again the limits.
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Skak, Nikolaj; Elhauge, Torben; Dayno, Jeffrey M; Lindhardt, Karsten
A novel technology platform (Guardian™ Technology, Egalet Corporation, Wayne, PA) was used to manufacture morphine abuse-deterrent (AD), extended-release (ER), injection-molded tablets (morphine-ADER-IMT; ARYMO® ER [morphine sulfate] ER tablets; Egalet Corporation), a recently approved morphine product with AD labeling. The aim of this article is to highlight how the features of Guardian™ Technology are linked to the ER profile and AD characteristics of morphine-ADER-IMT. The ER profile of morphine-ADER-IMT is attributed to the precise release of morphine from the polymer matrix. The approved dosage strengths of morphine-ADER-IMT are bioequivalent to corresponding dosage strengths of morphine ER (MS Contin®; Purdue Pharma LP, Stamford, CT). Morphine-ADER-IMT was very resistant to physical manipulations intended to reduce particle size, with <10 percent of particles being reduced to <500µm, regarded by the US Food and Drug Administration as a relevant cutoff for potential insufflation in their generic solid oral AD opioid guidance. Furthermore, morphine was not readily extracted from the polymer matrix of morphine-ADER-IMT in small- or large-volume solvent extraction studies that evaluated the potential for intravenous and oral abuse. The ER profile and AD characteristics of morphine-ADER-IMT are a result of Guardian™ Technology. The combination of the polyethylene oxide matrix and the use of injection molding differentiate morphine-ADER-IMT from other approved AD opioids that deter abuse using physical and chemical barriers. The high degree of flexibility of the Guardian™ Technology enables the development of products that can be tailored to almost any desired release profile; as such, it is a technology platform that may be useful for the development of a wide range of pharmaceutical products.
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Marmur, Ellen S; Al Quran, Hanadi; De Sa Earp, Ana Paula; Yoo, Jane Y
2009-12-01
The process of skin aging is not limited to the face but involves every part of the body, including the hands. A common manifestation of aging of the hands is the loss of volume, which occurs as the skin loses its subcutaneous fat. Injectable dermal fillers have surfaced as a popular method to address such deficiencies. To report the use of calcium hydroxylapatite (CaHA) to address lost volume. Five female subjects with soft tissue deficiency of the dorsa of the hands were enrolled at Mount Sinai Medical Center. A solution of CaHA with 2% lidocaine in amounts of 0.3 to 1.0 mL was injected interdigitally at each of three to five insertion sites; the sites were massaged and molded up to three times to ensure an optimal cosmetic end point. Subjects were seen for a follow-up visit after 1, 4, 16, and 24 weeks. With a single injection, all subjects reached their correction goals without requiring any touch-ups. At the 24-week visit, the subjects retained the filling effect, with no adverse events and high patient satisfaction. CaHA, a new, easily injectable, safe dermal filler, has emerged as an excellent option for soft tissue augmentation in aging hands.
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DOE Office of Scientific and Technical Information (OSTI.GOV)
Nguyen, Ba Nghiep; Fifield, Leonard S.; Mori, Steven
During the third quarter of FY 2015, the following technical progress has been made toward project milestones: 1) Magna oversaw the tool build and prepared the molding plan for the complex part of Phase II. 2) PlastiComp hosted a visit by Magna and Toyota on April 23rd to finalize the molding scope and schedule. The plan for molding trials including selection of molding parameters for both LFT and D-LFT for the U-shape complex part was established. 3) Toyota shipped the U-shape complex part tool to Magna on May 28th, 2015. 4) Plasticomp provided 30wt% LCF/PP and 30wt% LCF/PA66 compounded pelletsmore » to Magna for molding the complex part. 5) Magna performed preliminary molding trials on June 2nd, 2015 to validate wall thickness, fill profile, tool temperature and shot size requirements for the complex part. 6) Magna performed the first complex part run on June 16th and 17th, 2015 at Magna’s Composite Centre of Excellence in Concord, ON, Canada. Dale Roland of Plasticomp, and Umesh Gandhi of Toyota also attended the molding. 7) Magna discussed and finalized the plan with PNNL and the team for cutting samples from molded parts at selected locations for fiber orientation and length measurements. 8) Magna provided the computer-aided design (CAD) files of the complex parts with and without ribs to PNNL and Autodesk to build the corresponding ASMI models for injection molding simulations. Magna also provided the actual parameters used. 9) Plasticomp’s provided knowledge and experience of molding LCF materials essential to the successful molding of the parts including optimization of fill speed, tool temperatures, and plasticizing conditions for the 30wt% LCF/PP and 30wt% LCF/PA66 materials in both rib and non-rib versions. 10) Magna molded additional parts for evaluation of mechanical property testing including torsional stiffness on June 29th and 30th, 2015 at Magna’s Composite Center of Excellence. 11) Toyota began preparation for the torsion test of the specimens. Preparation of a computer-aided engineering (CAE) model to predict the performance is in progress. 12) Autodesk fixed an error in the implementation of the proper orthogonal decomposition (POD) calculation of fiber length that had caused the ASMI solution to crash and provided an updated build of ASMI containing the fix. 13)Autodesk reviewed and provided feedback for the complex part molding and measurement locations. 14) Autodesk provided support to set up the workflow for ASMI-ABAQUS® analysis, and provided a fix and workaround for a bug in the ASMI-ABAQUS® output command. 15) Autodesk helped build ASMI analysis models for the complex parts with and without ribs. 16) Autodesk worked on improving the orientation prediction accuracy in the shearing layer for 3D meshes based on comparison to measured data of the plaque moldings. 17) PNNL installed a new ASMI version received from Autodesk and performed comparative analyses to assess mid-plane versus 3D fiber length predictions using the full fiber length model and the reduced-order model (ROM) using POD. 18) PNNL presented the project scope, accomplishments, significant results and future plans to DOE and the USCAR Materials Tech Team on June 3rd, 2015. 19) PNNL discussed the cutting of samples from molded parts and finalized a plan with Magna and the team suggesting the sample size, locations and number of samples per location. 20) PNNL and Autodesk built ASMI models for the complex parts with and without ribs, and preliminary analyses of the part with ribs were conducted using the actual molding parameters received from Magna. 21) PNNL worked on a procedure to extract fiber orientation and length results from a 3D ASMI analysis to a 3D ABAQUS model. This procedure is essential to import ASMI fiber orientation and length to a 3D ABAQUS model of the part allowing future part structural analysis for weight reduction study.« less
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NASA Astrophysics Data System (ADS)
Chen, L. P.; He, L. P.; Chen, D. C.; Lu, G.; Li, W. J.; Yuan, J. M.
2017-01-01
The warpage deformation plays an important role on the performance of automobile interior components fabricated with natural fiber reinforced composites. The present work investigated the influence of process parameters on the warpage behavior of A pillar trim made of ramie fiber (RF) reinforced polypropylene (PP) composites (RF/PP) via numerical simulation with orthogonal experiment method and range analysis. The results indicated that fiber addition and packing pressure were the most important factors affecting warpage. The A pillar trim can achieved the minimum warpage value as of 2.124 mm under the optimum parameters. The optimal process parameters are: 70% percent of the default value of injection pressure for the packing pressure, 20 wt% for the fiber addition, 185 °C for the melt °C for the mold temperature, 7 s for the filling time and 17 s for the packing time.
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Thermo-mechanical simulation of liquid-supported stretch blow molding
DOE Office of Scientific and Technical Information (OSTI.GOV)
Zimmer, J.; Stommel, M.
2015-05-22
Stretch blow molding is the well-established plastics forming method to produce Polyehtylene therephtalate (PET) bottles. An injection molded preform is heated up above the PET glass transition temperature (Tg∼85°C) and subsequently inflated by pressurized air into a closed cavity. In the follow-up filling process, the resulting bottle is filled with the final product. A recently developed modification of the process combines the blowing and filling stages by directly using the final liquid product to inflate the preform. In a previously published paper, a mechanical simulation and successful evaluation of this liquid-driven stretch blow molding process was presented. In this way,more » a realistic process parameter dependent simulation of the preform deformation throughout the forming process was enabled, whereas the preform temperature evolution during forming was neglected. However, the formability of the preform is highly reduced when the temperature sinks below Tg during forming. Experimental investigations show temperature-induced failure cases due to the fast heat transfer between hot preform and cold liquid. Therefore, in this paper, a process dependent simulation of the temperature evolution during processing to avoid preform failure is presented. For this purpose, the previously developed mechanical model is used to extract the time dependent thickness evolution. This information serves as input for the heat transfer simulation. The required material parameters are calibrated from preform cooling experiments recorded with an infrared-camera. Furthermore, the high deformation ratios during processing lead to strain induced crystallization. This exothermal reaction is included into the simulation by extracting data from preform measurements at different stages of deformation via Differential Scanning Calorimetry (DSC). Finally, the thermal simulation model is evaluated by free forming experiments, recorded by a high-speed infrared camera.« less
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DOE Office of Scientific and Technical Information (OSTI.GOV)
Nick Cannell; Dr. Mark Samonds; Adi Sholapurwalla
The investment casting process is an expendable mold process where wax patterns of the part and rigging are molded, assembled, shelled and melted to produce a ceramic mold matching the shape of the component to be cast. Investment casting is an important manufacturing method for critical parts because of the ability to maintain dimensional shape and tolerances. However, these tolerances can be easily exceeded if the molding components do not maintain their individual shapes well. In the investment casting process there are several opportunities for the final casting shape to not maintain the intended size and shape, such as shrinkagemore » of the wax in the injection tool, the modification of the shape during shell heating, and with the thermal shrink and distortion in the casting process. Studies have been completed to look at the casting and shell distortions through the process in earlier phases of this project. Dr. Adrian Sabau at Oak Ridge National Labs performed characterizations and validations of 17-4 PH stainless steel in primarily fused silica shell systems with good agreement between analysis results and experimental data. Further tasks provided material property measurements of wax and methodology for employing a viscoelastic definition of wax materials into software. The final set of tasks involved the implementation of the findings into the commercial casting analysis software ProCAST, owned and maintained by ESI Group. This included: o the transfer of the wax material property data from its raw form into separate temperature-dependent thermophysical and mechanical property datasets o adding this wax material property data into an easily viewable and modifiable user interface within the pre-processing application of the ProCAST suite, namely PreCAST o and validating the data and viscoelastic wax model with respect to experimental results« less
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Method for encapsulating hazardous wastes using a staged mold
Unger, Samuel L.; Telles, Rodney W.; Lubowitz, Hyman R.
1989-01-01
A staged mold and method for stabilizing hazardous wastes for final disposal by molding an agglomerate of the hazardous wastes and encapsulating the agglomerate. Three stages are employed in the process. In the first stage, a first mold body is positioned on a first mold base, a mixture of the hazardous wastes and a thermosetting plastic is loaded into the mold, the mixture is mechanically compressed, heat is applied to cure the mixture to form a rigid agglomerate, and the first mold body is removed leaving the agglomerate sitting on the first mold base. In the second stage, a clamshell second mold body is positioned around the agglomerate and the first mold base, a powdered thermoplastic resin is poured on top of the agglomerate and in the gap between the sides of the agglomerate and the second mold body, the thermoplastic is compressed, heat is applied to melt the thermoplastic, and the plastic is cooled jacketing the agglomerate on the top and sides. In the third stage, the mold with the jacketed agglomerate is inverted, the first mold base is removed exposing the former bottom of the agglomerate, powdered thermoplastic is poured over the former bottom, the first mold base is replaced to compress the thermoplastic, heat is applied to melt the new thermoplastic and the top part of the jacket on the sides, the plastic is cooled jacketing the bottom and fusing with the jacketing on the sides to complete the seamless encapsulation of the agglomerate.
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Process of modifying a cable end
Roose, L.D.
1995-08-01
End moldings for high-voltage cables are described wherein the dielectric insulator of the cable is heated and molded to conform to a desired shape. As a consequence, high quality substantially bubble-free cable connectors suitable for mating to premanufactured fittings are made. Disclosed are a method for making the cable connectors either in the field or in a factory, molds suitable for use with the method, and the molded cable connectors, themselves. 5 figs.
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Spiral optical designs for nonimaging applications
NASA Astrophysics Data System (ADS)
Zamora, Pablo; Benítez, Pablo; Miñano, Juan C.; Vilaplana, Juan; Buljan, Marina
2011-10-01
Manufacturing technologies as injection molding or embossing specify their production limits for minimum radii of the vertices or draft angle for demolding, for instance. In some demanding nonimaging applications, these restrictions may limit the system optical efficiency or affect the generation of undesired artifacts on the illumination pattern. A novel manufacturing concept is presented here, in which the optical surfaces are not obtained from the usual revolution symmetry with respect to a central axis (z axis), but they are calculated as free-form surfaces describing a spiral trajectory around z axis. The main advantage of this new concept lies in the manufacturing process: a molded piece can be easily separated from its mold just by applying a combination of rotational movement around axis z and linear movement along axis z, even for negative draft angles. Some of these spiral symmetry examples will be shown here, as well as their simulated results.
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Spiral nonimaging optical designs
NASA Astrophysics Data System (ADS)
Zamora, Pablo; Benítez, Pablo; Miñano, Juan C.; Vilaplana, Juan
2011-10-01
Manufacturing technologies as injection molding or embossing specify their production limits for minimum radii of the vertices or draft angle for demolding, for instance. In some demanding nonimaging applications, these restrictions may limit the system optical efficiency or affect the generation of undesired artifacts on the illumination pattern. A novel manufacturing concept is presented here, in which the optical surfaces are not obtained from the usual revolution symmetry with respect to a central axis (z axis), but they are calculated as free-form surfaces describing a spiral trajectory around z axis. The main advantage of this new concept lies in the manufacturing process: a molded piece can be easily separated from its mold just by applying a combination of rotational movement around axis z and linear movement along axis z, even for negative draft angles. Some of these spiral symmetry examples will be shown here, as well as their simulated results.
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Novel freeform optical surface design with spiral symmetry
NASA Astrophysics Data System (ADS)
Zamora, Pablo; Benítez, Pablo; Miñano, Juan C.; Vilaplana, Juan
2011-10-01
Manufacturing technologies as injection molding or embossing specify their production limits for minimum radii of the vertices or draft angle for demolding, for instance. These restrictions may limit the system optical efficiency or affect the generation of undesired artifacts on the illumination pattern when dealing with optical design. A novel manufacturing concept is presented here, in which the optical surfaces are not obtained from the usual revolution symmetry with respect to a central axis (z axis), but they are calculated as free-form surfaces describing a spiral trajectory around z axis. The main advantage of this new concept lies in the manufacturing process: a molded piece can be easily separated from its mold just by applying a combination of rotational movement around axis z and linear movement along axis z, even for negative draft angles. The general designing procedure will be described in detail.
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Method for molding ceramic powders
Janney, Mark A.
1990-01-01
A method for molding ceramic powders comprises forming a slurry mixture including ceramic powder, a dispersant for the metal-containing powder, and a monomer solution. The monomer solution includes at least one multifunctional monomer, a free-radical initiator, and an organic solvent. The slurry mixture is transferred to a mold, and the mold containing the slurry mixture is heated to polymerize and crosslink the monomer and form a firm polymer-solvent gel matrix. The solid product may be removed from the mold and heated to first remove the solvent and subsequently remove the polymer, whereafter the product may be sintered.
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Method for molding ceramic powders
Janney, M.A.
1990-01-16
A method for molding ceramic powders comprises forming a slurry mixture including ceramic powder, a dispersant for the metal-containing powder, and a monomer solution. The monomer solution includes at least one multifunctional monomer, a free-radical initiator, and an organic solvent. The slurry mixture is transferred to a mold, and the mold containing the slurry mixture is heated to polymerize and crosslink the monomer and form a firm polymer-solvent gel matrix. The solid product may be removed from the mold and heated to first remove the solvent and subsequently remove the polymer, where after the product may be sintered.
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DOE Office of Scientific and Technical Information (OSTI.GOV)
Nick Cannell; Adrian S. Sabau
The investment casting process allows the production of complex-shape parts and close dimensional tolerances. One of the most important phases in the investment casting process is the design of the pattern die. Pattern dies are used to create wax patterns by injecting wax into dies. The first part of the project involved preparation of reports on the state of the art at that time for all the areas under consideration (die-wax, wax-shell, and shell-alloy). The primary R&D focus during Phase I was on the wax material since the least was known about it. The main R&D accomplishments during this phasemore » were determination of procedures for obtaining the thermal conductivity and viscoelastic properties of an unfilled wax and validating those procedures. Phase II focused on die-wax and shell-alloy systems. A wax material model was developed based on results obtained during the previous R&D phase, and a die-wax model was successfully incorporated into and used in commercial computer programs. Current computer simulation programs have complementary features. A viscoelastic module was available in ABAQUS but unavailable in ProCAST, while the mold-filling module was available in ProCAST but unavailable in ABAQUS. Thus, the numerical simulation results were only in good qualitative agreement with experimental results, the predicted shrinkage factors being approximately 2.5 times larger than those measured. Significant progress was made, and results showed that the testing and modeling of wax material had great potential for industrial applications. Additional R&D focus was placed on one shell-alloy system. The fused-silica shell mold and A356 aluminum alloy were considered. The experimental part of the program was conducted at ORNL and commercial foundries, where wax patterns were injected, molds were invested, and alloys were poured. It was very important to obtain accurate temperature data from actual castings, and significant effort was made to obtain temperature profiles in the shell mold. A model for thermal radiation within the shell mold was developed, and the thermal model was successfully validated using ProCAST. Since the fused silica shells had the lowest thermal expansion properties in the industry, the dewaxing phase, including the coupling between wax-shell systems, was neglected. The prefiring of the empty shell mold was considered in the model, and the shell mold was limited to a pure elastic material. The alloy dimensions were obtained from numerical simulations only with coupled shell-alloy systems. The alloy dimensions were in excellent quantitative agreement with experimental data, validating the deformation module. For actual parts, however, the creep properties of the shell molds must also be obtained, modeled, and validated.« less