Optimisation of Micro Injection Moulding Process through Design of Experiments

Relationship between the Polymer Blend Using Chitosan, Polyethylene Glycol, Polyvinyl Alcohol, Polyvinylpyrrolidone, and Antimicrobial Activities against Staphylococcus aureus

The findings from Pareto charts, main effect plots, and interaction plots demonstrate the importance of polymer concentration. Increasing concentration improves the inhibition percentage and decreases the MIC50. However, the primary factor that influences these changes is chitosan (CS). Additionally, the interaction between CS and PVP, along with other polymers, plays a crucial role in achieving better antimicrobial effects. These results enhance our understanding of the antimicrobial properties of the studied polymers and offer valuable insights for developing effective antimicrobial formulations. The MIC50 value of M1-M16 was at a polymer percentage of 12.5%. At 12.5% polymer percentage, with the limits of [PVA], [PEG], and [PVP] being 0.002-0.004 g/mL and [CS] being 0.001-0.002 g/mL, using the 2-level full factorial method, the inhibition percentage is equal to 174.1 - 27,812 PVA - 18,561 PVP - 25,960 PEG - 38,752 CS + 9,263,047 PVA*PVP + 10,430,763 PVA*PEG + 15,397,157 PVA*CS + 7,088,313 PVP*PEG + 7,841,221 PVP*CS + 14,228,046 PEG*CS - 3,367,292,860 PVA*PVP*PEG - 5,671,998,721 PVA*PVP*CS - 6,619,041,275 PVA*PEG*CS - 3,917,095,529 PVP*PEG*CS + 2,273,661,969,470 PVA*PVP*PEG*CS. Theoretically, the most economical concentrations of PVA, PVP, PEG, and CS are 0.002, 0.002, 0.002, and 0.001 mg/mL at a concentration of 12.5% to reach an inhibition percentage of 99.162%, which coincides with the MBC value.

Effect of Process Parameters on Flow Length and Flash Formation in Injection Moulding of High Aspect Ratio Polymeric Micro Features

This paper reports an investigation of the effects of process parameters on the quality characteristics of polymeric parts produced by micro injection moulding (μIM) with two different materials. Four injection moulding process parameters (injection velocity, holding pressure, melt temperature and mould temperature) were investigated using Polypropylene (PP) and Acrylonitrile Butadiene Styrene (ABS). Three key characteristics of the mouldings were evaluated with respect to process settings and the material employed: part mass, flow length and flash formation. The experimentation employs a test part with four micro fingers with different aspect ratios (from 21 up to 150) and was carried out according to the Design of Experiments (DOE) statistical technique. The results show that holding pressure and injection velocity are the most influential parameters on part mass with a direct effect for both materials. Both parameters have a similar effect on flow length for both PP and ABS at all aspect ratios and have higher effects as the feature thickness decreased below 300 μm. The study shows that for the investigated materials the injection speed and packing pressure were the most influential parameters for increasing the amount of flash formation, with relative effects consistent for both materials. Higher melt and mould temperatures settings were less influential parameters for increasing the flash amount when moulding with both materials. Of the two investigated materials, PP was the one exhibiting more flash formation as compared with ABS, when corresponding injection moulding parameters settings for both materials were considered.

Simulation of mechanical behavior and optimization of simulated injection molding process for PLA based antibacterial composite and nanocomposite bone screws using central composite design

In this study, injection molding of three poly lactic acid (PLA) based bone screws was simulated and optimized through minimizing the shrinkage and warpage of the bone screws. The optimization was carried out by investigating the process factors such as coolant temperature, mold temperature, melt temperature, packing time, injection time, and packing pressure. A response surface methodology (RSM), based on the central composite design (CCD), was used to determine the effects of the process factors on the PLA based bone screws. Upon applying the method of maximizing the desirability function, optimization of the factors gave the lowest warpage and shrinkage for nanocomposite PLA bone screw (PLA9). Moreover, PLA9 has the greatest desirability among the selected materials for bone screw injection molding. Meanwhile, a finite element analysis (FE analysis) was also performed to determine the force values and concentration points which cause yielding of the screws under certain conditions. The Von-Mises stress distribution showed that PLA9 screw is more resistant against the highest loads as compared to the other ones. Finally, according to the results of injection molding simulations, the design of experiments (DOE) and structural analysis, PLA9 screw is recommended as the best candidate for the production of biomedical materials among all the three types of screws.