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Polymers
Special Issues
Molding Process of Polymers and Composites
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Molding Process of Polymers and Composites

A special issue of Polymers (ISSN 2073-4360). This special issue belongs to the section "Polymer Processing and Engineering".

Deadline for manuscript submissions: 15 February 2025 | Viewed by 3955

Special Issue Editors

Prof. Dr. Chao-Ming Lin

E-Mail Website
Guest Editor
Department of Mechanical and Energy Engineering, National Chiayi University, Chiayi 600355, Taiwan
Interests: polymer processing; injection molding; mold design; mechanical design; materials analysis
Dr. Chia-Chin Wu

E-Mail Website
Guest Editor
Department of Mold and Die Engineering, National Kaohsiung University of Science and Technology (NKUST), Kaohsiung City 807618, Taiwan
Interests: structural vibration; fatigue and fracture; finite-element analysis; hyperelastic rubber material; mechanical design

Special Issue Information

Dear Colleagues,

This Special Issue will focus on the innovative aspects of the molding process of polymers and composites and will address a wide range of topics, from process design, experimental analysis, numerical simulations, material behavior, processing parameters and product quality enhancement. This Special Issue aims to compile cutting-edge research that contributes significantly to the advancement of molding technologies and material science. Molding processes are crucial for the development of the high-performance and complex-shaped materials employed across various industries. This Special Issue will provide a platform for researchers, engineers, and practitioners to share their latest findings and innovations in the field. The scope of this Special Issue includes, but is not limited to, the following areas:

  1. Innovative design and optimization of molding processes that lead to enhanced material properties and component functionalities.
  2. Experimental analysis and characterizations focusing on the relationship between process parameters and material behavior.
  3. Advanced numerical simulations that provide insights into the flow, heat transfer, and mechanical properties of polymers and composites during molding.
  4. Investigations into the effects of processing parameters on the quality of the molded products, including studies on minimizing defects and improving dimensional stability.
  5. Development of new materials and composites tailored for specific molding techniques, with the aim of improving performance and sustainability.

Prof. Dr. Chao-Ming Lin
Dr. Chia-Chin Wu
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Polymers is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2700 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • molding process
  • polymers
  • composites
  • process design
  • experimental analysis
  • numerical simulation
  • product quality
  • material behavior

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Further information on MDPI's Special Issue polices can be found here.

Published Papers (4 papers)

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Research

24 pages, 5087 KiB  
Article
Optimization of Metal Injection Molding Processing Conditions for Reducing Black Lines and Meld Lines in Bone Plates
by Chao-Ming Lin, Po-Yu Yen and Chung-Ming Tan
Polymers 2024, 16(23), 3241; https://doi.org/10.3390/polym16233241 - 22 Nov 2024
Viewed by 470
Abstract
The bone plates used in surgery to assist in fracture healing are often manufactured by metal injection molding (MIM) using a feedstock material consisting of metal powder and polymer binder. However, if the local powder concentration is too low or uneven, black lines [...] Read more.
The bone plates used in surgery to assist in fracture healing are often manufactured by metal injection molding (MIM) using a feedstock material consisting of metal powder and polymer binder. However, if the local powder concentration is too low or uneven, black lines may be formed, which impair the product appearance. Furthermore, if the melding temperature is too low, it can lead to meld lines and reduced mechanical properties. Accordingly, this study combines mold flow analysis simulations with the single-objective Taguchi robust design method to determine the MIM processing conditions that optimize the powder concentration and melding temperature. Grey relational analysis (GRA) is then used to establish the processing conditions that simultaneously optimize both MIM objectives. It is found that the processing conditions determined through GRA provide a significant improvement over the original design; however, the experimental outcomes are poorer than those achieved through the single-objective Taguchi experiments since the melt temperature effect suppresses that of all the other processing conditions. Consequently, a robust multi-criteria optimization (RMCO) technique is employed to improve the optimization outcome by identifying the dominant factors in the MIM process and fixing them at optimal levels to redesign the Taguchi experiments to optimize the non-primary factors. It is shown that the RMCO method eliminates interference between the multiple factors and hence provides an improved multi-objective optimization outcome. Overall, the integrated framework proposed in this study advances the optimization of the MIM process for bone plates and leads to improved product quality and performance. Full article
(This article belongs to the Special Issue Molding Process of Polymers and Composites)
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30 pages, 14756 KiB  
Article
Simulation and Experimental Study on Enhancing Dimensional Accuracy of Polycarbonate Light Guides
by Jiri Vanek, Martin Ovsik, Jan Hanzlik and Michal Stanek
Polymers 2024, 16(22), 3203; https://doi.org/10.3390/polym16223203 - 19 Nov 2024
Viewed by 347
Abstract
This research investigates the adaptation of conventional injection-molding techniques for producing thick-walled polycarbonate optical components, specifically targeting their application in automotive light guides. With the automotive industry’s growing demand for reliable yet cost-efficient optical products, the study examines how traditional injection-molding processes can [...] Read more.
This research investigates the adaptation of conventional injection-molding techniques for producing thick-walled polycarbonate optical components, specifically targeting their application in automotive light guides. With the automotive industry’s growing demand for reliable yet cost-efficient optical products, the study examines how traditional injection-molding processes can be refined to enhance dimensional accuracy and reduce defects. Simulations and experimental trials were conducted to evaluate the impact of critical process parameters, such as melt temperature, mold temperature, injection pressure, and gate design, on the overall quality of the final components. The results show that by carefully optimizing these parameters, it is possible to significantly reduce common defects like warpage, surface imperfections, and dimensional instability. This research highlights the potential of existing molding techniques to meet high industry standards while maintaining cost-effectiveness, offering valuable guidance for manufacturers aiming to produce high-quality optical components for demanding applications like automotive lighting. Full article
(This article belongs to the Special Issue Molding Process of Polymers and Composites)
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32 pages, 14147 KiB  
Article
Study of Injection Molding Process to Improve Geometrical Quality of Thick-Walled Polycarbonate Optical Lenses by Reducing Sink Marks
by Jiri Vanek, Martin Ovsik, Michal Stanek, Jan Hanzlik and Vladimir Pata
Polymers 2024, 16(16), 2318; https://doi.org/10.3390/polym16162318 - 16 Aug 2024
Viewed by 942
Abstract
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 [...] Read more.
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. Full article
(This article belongs to the Special Issue Molding Process of Polymers and Composites)
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21 pages, 8143 KiB  
Article
Debinding of Yttria-Stabilised Zirconia/Bimodal Stainless Steel 316L Bi-Materials Produced through Two-Component Micro-Powder Injection Moulding
by Al Basir, Abu Bakar Sulong, Norhamidi Muhamad, Afifah Z. Juri, Nashrah Hani Jamadon, Farhana Mohd Foudzi and Nabilah Afiqah Mohd Radzuan
Polymers 2024, 16(13), 1831; https://doi.org/10.3390/polym16131831 - 27 Jun 2024
Viewed by 1716
Abstract
The fabrication of bi-material micro-components via two-component micro-powder injection moulding (2C-µPIM) from 3 mol% yttria-stabilised zirconia (3YSZ) and micro/nano bimodal stainless steel 316L (SS 316L) powders has received insufficient attention. Apart from this, retaining the bonding between ceramic and metal at different processing [...] Read more.
The fabrication of bi-material micro-components via two-component micro-powder injection moulding (2C-µPIM) from 3 mol% yttria-stabilised zirconia (3YSZ) and micro/nano bimodal stainless steel 316L (SS 316L) powders has received insufficient attention. Apart from this, retaining the bonding between ceramic and metal at different processing stages of 2C-µPIM is challenging. This study investigated the solvent and thermal debinding mechanisms of green bi-material micro-parts of 3YSZ and bimodal SS 316L without collapsing the ceramic/metal joining. In this research, feedstocks were prepared by integrating the powders individually with palm stearin and low-density polyethylene binders. The results demonstrated that during the solvent debinding process, the palm stearin removal rate in the bi-materials composed of 3YSZ and bimodally configured SS 316L feedstocks intensified with an increase in temperature. The establishment of interconnected pores in the solvent-debound components facilitated the thermal debinding process, which removed 99% of the binder system. Following sintering, the debound bi-materials exhibited a relative density of 95.3%. According to a study of the microstructures using field emission scanning electron microscopy, an adequate bond between 3YSZ and bimodal SS 316L was established in the micro-part after sintering. The bi-material sintered at 1350 °C had the highest hardness of 1017.4 HV along the joining region. Full article
(This article belongs to the Special Issue Molding Process of Polymers and Composites)
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