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Correlating nano-scale surface replication accuracy and cavity temperature in micro-injection moulding using in-line process control and high-speed thermal imaging
Baruffi, F. Gülçür, Mert, Calaon, M. Romano, J.-M. Penchev, P. Dimov, S. Whiteside, Benjamin R. Tosello, G.
Baruffi, F.
Gülçür, Mert,
Calaon, M.
Romano, J.-M.
Penchev, P.
Dimov, S.
Whiteside, Benjamin R.
Tosello, G.
Publication Date
2019-11, 2019-11
End of Embargo
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© 2019 Elsevier. Reproduced in accordance with the publisher's self-archiving policy. This manuscript version is made available under the CC-BY-NC-ND 4.0 license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
Peer-Reviewed
Yes
Open Access status
Accepted for publication
2019-08-20
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Awarded
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Abstract
Micro-injection moulding (μIM) stands out as preferable technology to enable the mass production of polymeric
components with micro- and nano-structured surfaces. One of the major challenges of these processes is related
to the quality assurance of the manufactured surfaces: the time needed to perform accurate 3D surface acquisitions
is typically much longer than a single moulding cycle, thus making impossible to integrate in-line
measurements in the process chain. In this work, the authors proposed a novel solution to this problem by
defining a process monitoring strategy aiming at linking sensitive in-line monitored process variables with the
replication quality. A nano-structured surface for antibacterial applications was manufactured on a metal insert
by laser structuring and replicated using two different polymers, polyoxymethylene (POM) and polycarbonate
(PC). The replication accuracy was determined using a laser scanning confocal microscope and its dependence
on the variation of the main μIM parameters was studied using a Design of Experiments (DoE) experimental
approach. During each process cycle, the temperature distribution of the polymer inside the cavity was measured
using a high-speed infrared camera by means of a sapphire window mounted in the movable plate of the mould.
The temperature measurements showed a high level of correlation with the replication performance of the μIM
process, thus providing a fast and effective way to control the quality of the moulded surfaces in-line.
Version
Accepted manuscript
Citation
Baruffi F, Gülçür M, Calaon M et al (2019) Correlating nano-scale surface replication accuracy and cavity temperature in micro-injection moulding using in-line process control and high-speed thermal imaging. Journal of Manufacturing Processes. 47: 367-381.
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Article