Condition Monitoring in Micro-Injection Moulding

This chapter looks at the condition monitoring of the micro-injection moulding process (µ-IM). This manufacturing process has been applied successfully to a wide range of products in the micro-scale and is also an appropriate technology for manufacturing meso-parts with both micro- and nano-features. Improvement in the quality and the accuracy of parts made from polymers can be successfully achieved by determining the optimum conditions for replication. Process control in manufacturing is critical, and condition monitoring of µ-IM is a control method for improved understanding of the effects of selected parameter settings. This chapter reports on the condition monitoring methods used to improve the factors that affect part’s quality. For each of the examples, the Taguchi design of experiments (DOE) method is used together with demonstrations of various experimental set-ups and the acquisition of data. The chapter advises on the obtainment of information regarding the behaviour of the µ-IM and the significant factors affecting the process. The selected case studies demonstrate the condition monitoring of the cavity pressure, forces, temperature distribution and air evacuation. For each, the research findings are discussed and conclusions are made.