3D thickness distributions of plano lenses as a means of cavity pressure characterization in microinjection molding

This work presents a novel nondestructive cavity pressure characterization approach in microinjection molding (μIM) through measuring 3D part thickness distributions. For this purpose, a plano lens was designed and experiments based on Taguchi method were conducted. Both overall and local lens thickness distributions under various process conditions were analyzed in terms of their relevance with the cavity pressure during molding. Unexpectedly, a reliable linear regression model was developed fulfilling nondestructive multi-point or even continuous cavity pressure characterization with the overall lens thickness distribution. Furthermore, the topography of the constructed 3D thickness surface was found to depend on both process condition and measuring position. Finally, the process conditions were optimized for obtaining uniform distributions of both 3D thickness and cavity pressure.