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dc.contributor.authorGülçür, Mert
dc.contributor.authorBrown, Elaine C.
dc.contributor.authorGough, Timothy D.
dc.contributor.authorRomano, J.-M.
dc.contributor.authorPenchev, P.
dc.contributor.authorDimov, Stefan
dc.contributor.authorWhiteside, Benjamin R.
dc.date.accessioned2020-09-25T14:45:30Z
dc.date.available2020-09-25T14:45:30Z
dc.date.issued2020-10
dc.identifier.citationGülçür M, Brown E, Gough TD et al (2020) Ultrasonic micromoulding: Process characterisation using extensive in-line monitoring for micro-scaled products. Journal of Manufacturing Processes. 58: 289-301.en_US
dc.identifier.urihttp://hdl.handle.net/10454/18029
dc.descriptionYesen_US
dc.description.abstractIndustry-standard quality management systems such as Six Sigma and emerging Industry 4.0 compliant production processes demonstrate the importance of in-line condition monitoring of manufacturing methods for achieving the highest levels of product quality. Measurement data collected as the process is running can inform the operator about unexpected changes in machine operation or raw materials that could negatively impact production; and offer an opportunity for a process control intervention to stabilise production. However, micro-manufacturing production lines can pose a challenging environment for deploying such systems, since processing events can occur extremely rapidly and in harsh environments. Moreover, the small scale of micro-nano featured components can make sensor installation even more problematic. Recently, ultrasonic micromoulding has drawn attention in niche markets due to its unique advantages for processing thermoplastics as a new micro-manufacturing technology. The process differs from conventional moulding significantly by eliminating the need for a plasticising screw and using direct application of ultrasonic energy to melt the polymer. This offers numerous benefits such as decrease in energy usage, moulding at lower pressures, easier cleaning, and reduced material residence times, the latter which could be beneficial for pharma-grade polymers or polymers with active ingredients. However, very little work has been reported attempting to monitor the process using in-line measurements. This work aims to evaluate the characteristics of the ultrasonic micromoulding process for microinjection moulding of a microneedle array using a range of sensor technologies including: data recorded by the machine controller; a high-speed thermal camera and a cavity pressure transducer. The data has captured the highly dynamic process environment with a high degree of accuracy. The relationship between the process data and dimensional quality of the ultrasonically micromoulded products has been quantified and subsequently implemented as a cost-effective in-line quality assurance method.en_US
dc.description.sponsorshipHorizon 2020, the EU Framework Programme for Research and Innovation (Project ID: 674801). This research has also received funding and support from two other Horizon 2020 projects: HIMALAIA (Grant agreement No. 766871) and Laser4Fun (GA no. 675063)en_US
dc.language.isoenen_US
dc.relation.isreferencedbyhttps://doi.org/10.1016/j.jmapro.2020.08.033en_US
dc.rights© 2020 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 (https://creativecommons.org/licenses/by/4.0/)
dc.subjectUltrasonic micromouldigen_US
dc.subjectMicro-injection mouldingen_US
dc.subjectProcess monitoringen_US
dc.subjectData acquisitionen_US
dc.subjectPolymer replicationen_US
dc.subjectMicroneedlesen_US
dc.titleUltrasonic micromoulding: Process characterisation using extensive in-line monitoring for micro-scaled productsen_US
dc.status.refereedYesen_US
dc.date.Accepted2020-08-14
dc.date.application2020-08-19
dc.typeArticleen_US
dc.date.EndofEmbargo2022-08-20
dc.type.versionAccepted manuscripten_US
dc.description.publicnotesThe full-text of this article will be released for public view at the end of the publisher embargo on 20 Aug 2022.en_US
refterms.dateFOA2020-09-25T14:46:42Z


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