Study of injection molding process to improve geometrical quality of thick-walled polycarbonate optical lenses by reducing sink marks

Result code in IS VaVaI

<a href="https://www.isvavai.cz/riv?ss=detail&h=RIV%2F70883521%3A28110%2F24%3A63580560" target="_blank" >RIV/70883521:28110/24:63580560 - isvavai.cz</a>

Result on the web

<a href="https://www.mdpi.com/2073-4360/16/16/2318" target="_blank" >https://www.mdpi.com/2073-4360/16/16/2318</a>

DOI - Digital Object Identifier

<a href="http://dx.doi.org/10.3390/polym16162318" target="_blank" >10.3390/polym16162318</a>

Result language

angličtina

Original language name

Study of injection molding process to improve geometrical quality of thick-walled polycarbonate optical lenses by reducing sink marks

Original language description

This study investigates the challenges and potential of conventional injection molding for producing thick-walled optical components. The research primarily focuses on optimizing process parameters and mold design to enhance product quality. The methods include software simulations and experimental validation using polycarbonate test samples (optical lenses). Significant parameters such as melt temperature, mold temperature, injection pressure, and packing pressure were varied to assess their impact on geometric accuracy and visual properties. The results show that lower melt temperatures and higher mold temperatures significantly reduce the occurrence of dimensional defects. Additionally, the design of the gate system was found to be crucial in minimizing defects and ensuring uniform material flow. Effective packing pressure was essential in reducing volumetric shrinkage and sink marks. Furthermore, we monitored the deviation between the predicted and actual defects relative to the thickness of the sample wall. After optimization, the occurrence of obvious defects was eliminated across all sample thicknesses (lenses), and the impact of the critical defect, the sink mark on the planar side of the lens, was minimized. These findings demonstrate the substantial potential of conventional injection molding to produce high-quality thick-walled parts when these parameters are precisely controlled. This study provides valuable insights for the efficient design and manufacturing of optical components, addressing the growing demand for high-performance thick-walled plastic products.

Czech name

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Czech description

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Type

J_imp - Article in a specialist periodical, which is included in the Web of Science database

CEP classification

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OECD FORD branch

20301 - Mechanical engineering

Project

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Continuities

S - Specificky vyzkum na vysokych skolach

Publication year

2024

Confidentiality

S - Úplné a pravdivé údaje o projektu nepodléhají ochraně podle zvláštních právních předpisů

Name of the periodical

Polymers

ISSN

2073-4360

e-ISSN

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Volume of the periodical

16

Issue of the periodical within the volume

16

Country of publishing house

CH - SWITZERLAND

Number of pages

32

Pages from-to

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UT code for WoS article

001304829200001

EID of the result in the Scopus database

2-s2.0-85202435331