Scientific micro injection molding sounds a lot more like science fiction than fact. Many molders actually believe that the process is still impossible because it seems to require a microscope to ensure it is done properly. When you consider that people used to say the same thing about machining mold it is easy to see how this logic is flawed. Custom injection molds seem to be the perfect way to not only prove that it is possible, but to perfect and refine the process.
What It Is
The name itself implies what this method is: scientific micro injection molding transfers the plastic fill at a rate of 95% of the filled parts volume. There are five components to achieve this unique and complex molding method:
- A robust mold designed specifically to withstand the process
- A press sized and produced to create the correct injection pressure to eliminate the potential for pressure buildup
- A compatible resin that dries at a predictable rate
- Established parameters that optimize the resin’s properties and drying time
- A micro tool to test the process
Ensure that your beginning components work together, creating a product that fits your desired results. It is also critical that the team understands what needs to be done and how.
Scientific Molding Steps
The process is still in the early phases, which means that there are very specific steps to make it work properly.
- Conduct a study into the viscosity. This is part of most scientific molding processes, but is impossible with micro parts as the process is on too minute a level to study.
- Test the balance of the cavity.
- Study the drop in pressure during process execution. For micro processing, this means monitoring the overall pressure to ensure it is not nearing the established maximum.
- Determine the process window.
- Determining and executing the gate seal. It is a unique challenge to micro processing, but not impossible.
- Study the amount of time it requires to properly cool.
The steps may change and vary as the industry begins to accept the process. The more minds available to consider process and improvements, especially specific to the different fields in the industry, the more variety there will be to the steps in the future. For now, these steps prove that the process is not just possible in theory, it is possible in practice, particularly for custom injection molds that require more attention to detail.
Topics: Injection Mold Technology