Computer assisted micro-injection moulding

Focusing on micro-fabrication, industrial processes require new methods for the inexpensive, efficient and increased production of complex micro-objects. As such, the injection moulding process could be significantly improved by using newly developed 3D numerical and mathematical models. For simulating any process related to polymer flows with moving free boundaries, these tools could be extremely valuable in the process of micro-injection moulding.

Industrial Technologies

The new dimensions offered by current microtechnology enable the fabrication of very precise microstructures. Based on computer modelling techniques, the process parameters have been more accurately specified leading to an improved design of moulds. Nevertheless, the current 2D models are unsuitable for the modelling of structures with large surface to volume ratios, usually found in the injection or compression moulding processes. Furthermore, in this process of filling the micro-structures, extremely small space and time scales dominate and considerably affect the associated physical phenomena, such as visco-elastic and non-isothermal effects. To overcome these limitations, a new and reliable mathematical and numerical model has been developed for the simulation of 3D time-dependent polymer flows with moving free boundaries. This reliable method can be applied in the filling stage of several moulding processes, including the injection or compression moulding, resin transfer moulding and structural reaction injection moulding. Most importantly, it is valuable for the micro-injection moulding simulation, in order to produce high quality objects and structures in large volumes with the utmost precision and at minimal cost.