Program Overview

Precision and Micro Injection Molding Program

Overview

The manufacturing of precise and micro plastic parts requires an understanding of design, processing, and metrology. Micro injection molding is the technology used to manufacture plastics products characterized by tolerances in the micrometer range, or dimensions in the micrometer range, or by the presence of micro-and nano-features on their surface. Main applications are in the field of medical devices, implantable devices, electronics, sensors, and more.

Course Details

• Course Number: PLSM.7700
• Tuition: $1,500
• Format: In-Person Only
• Duration: 2 days (June 5-6)
• Instructor: Dr. Davide Masato

Program Content

Overview of Precision and Micro Injection Molding

• Definition of precision and micro injection molding: micro-scale parts, parts with micro-scale tolerances, textured parts.
• Differences with conventional injection molding: challenges and opportunities.
• Applications and examples: medical, electronics, sensors, etc.

Part Design for Micro Molding

• Material selection and characterization: requirements for precision and micro applications; amorphous vs. semi-crystalline; flow characteristics; thermal properties.
• Design for Manufacturing of precise and micro plastic products: mold filling, shrinkage and warpage, cooling.
• Design guidelines: wall thickness, parting lines, tolerances.
• The role of simulation: material characterization, model preparation, model parameters, analysis of the results.

Machine Technology

• Micro injection molding machines: scaled-down technologies, two-screw design, screw over plunger design, overmolding, process control and accuracy.

Mold Design and Tooling Technologies

• Design approach for micro injection molds: two-plate, three-plate, gating, ejection, cooling.
• Tooling Technologies: Micro milling, Micro-electro discharge machining, Lithography, Laser, Additive Manufacturing.

Metrology for Micro Molding

• Quality control: optical microscopy, atomic force microscopy, scanning electron microscopy, surface characterization, morphology characterization.

Process Monitoring and Optimization

• Effect of process parameters on micro molded parts quality, process consistency.
• Statistical process monitoring.

Case Studies

• Product and mold designs developed at Isometric Micromolding will be analyzed and discussed with the attendees.

Workshops

Attendees will use different types of micro injection molding machine and molds.

About the Instructor

Dr. Davide Masato received a B.S. in Mechanical Engineering (2011), an M.S. in Mechanical Engineering (2014) and a Ph.D. (2018) from the University of Padova in Italy. His research focuses on plastic product design, polymer processing technologies, sustainable manufacturing, and computer-aided engineering. Dr. Masato's research resulted in 35+ journal publications, 50+ conference presentations, 1 book chapter, and 3 patents.