Injection Molding: Continuing to Pave the path

for Bio-Polymers

Luis Onsurez- Engineering Technology

Mentor: Chris F. Wise

ObjectivesPhase 1

• To design a mold that can allow user to control injection process parameters

• Correlate the information seen in software packages such as MoldFlow and Solidworks to data obtained from modified mold

Phase 2• Redesign and manufacture new mold based on the three sources of data. • Begin analysis of Bio-polymers to map the polymers characteristics

The Injection Molding ProcessThe process of melting down a material and injecting

it into a cavity to form a shape or object.

-Hopper-Injection screw-Barrel-Nozzle-Sprue/Runner-Cavity

What are Bio-Polymers?

Bio-Polymers are a compound derived from plants

Environment Benefits

Pros • Reduces

dependency on Petroleum/ Fossil Fuels based polymers

• Can be produced from material found within the Country

Cons•Fairly new in Industry•Currently requires larger amounts of energy to produce than conventional thermoplastics

Current Mold Designs

• Coolant / Mold Contact

• Coolant Tunnel position

Pictures by DME Plastics

Initial Mold Design • Less Material

• Thermal Control through Forced Convection

• Reduction in variables that effect finished products

• Cavity based on ASTM Standard allows for further studies

• Allows the use of Bio-Polymer due to a constant mold cavity temperature

Changes to Mold Design

• Single shot design• Runner positioning• Runner design• Gas vents• Thermocouples

Applications of this Mold Design

• Thermoplastics

• Bio-Polymers

Test Preparation

• Cleaning Materials– Cleaning Compound

• Mold Preparation– Set Thermocouple– Mold Clamping

Data Acquisition Equipment

• Data Logger

• Power Supply

• Thermocouples

Material Testing

• Petroleum Based

– Polyethylene– Polypropylene

• Future Testing– Bio-Plastics (Bio-Polyester)– Tensile Testing

Results

• Currently Processing Phase 1 obtained Data Samples

• Computer Analysis– MoldFlow

– Solidworks/COSMOS

Special Thanks To

Chris Wise

Dr. Delia Valles

Andy Lawerence

MultiPlastics Inc

Professor Sonya Cooper

AMP

Charlie ParkKim ParkeyMatt SteeleProfessor Thomas JenkinsStudent Project Center StaffU.R.A. staff and mentorsNSF

References

• http://www.plastic-gear-manufacturer.com/

• http://www.seattlerobotics.org

• http://www.glue.umd.edu

• http://www.patentgenius.com/patent/5296174.html

• http://www.dmeuniversity.net/english/f1.cfm

• http://www.biopak.com.au/images/Resin%20handful.jpg

• http://www.thefreedictionary.com/injection+molding

• http://engr.bd.psu.edu/pkoch/plasticdesign/IM_Thermoplastic_files/image002.gif

• http://www.scudc.scu.edu/cmdoc/dg_doc/images/process/control/b1000002/02machin/machin.gif