doi: 10.3850/978-981-11-0749-8_743
Process Optimization for Injection Moulding of Passive Microwave Components
Steffen G. Scholz1, Tobias Mueller1, Leonardo Santos Machado1, Matteo Calaon2, Guido Tosello2, Stephane Dessors3, Manfred Prantl4 and Nathan Miller5
1Institute for Applied Computer Science, Karlsruhe Institute of Technology, Karlsruhe, Germany
2Department of Mechanical Engineering, Technical University of Denmark, Kgs. Lyngby, Denmark
3IPC, Bellignat, France
4Alicona Imaging GmbH, Raaba, Austria
5Flann Microwave Limited, Cornwall, United Kingdom
Abstract
The demand for micro components has increased during the last decade following the overall trend towards miniaturization. Injection moulding is the favoured technique for the mass manufacturing of micro components or larger parts with micro-structured areas due to its ability to cost effectively replicate very complex shapes, precise tolerances and in high numbers. In order to secure Europe’s leading role in the sector of micro-fabrication the capabilities of injection moulding need to be further developed.
In this research a product for telecommunication, a diplexer unit, has been manufactured utilizing the injection moulding process. A design of experiment study has been carried out, varying process parameters such as injection speed, holding pressure, mould- and barrel temperature. The replicated parts are characterized by measuring geometric features and the part weight. Using an evaluation algorithm for modelling, the influence of different moulding parameters on the final part quality was assessed. Firstly a process model and secondly a quality model has been calculated. The results shows that part quality can be controlled by monitoring characteristic numbers.
Keywords: Injection moulding, Process optimization, Accuracy, Metallization, Optical metrology.
