Applications of Process Simulation in Polymer-Based Products Injection Molding

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

Deadline for manuscript submissions: 30 September 2025 | Viewed by 258

Special Issue Editors


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Guest Editor
Department of Integrated Systems Engineering, The Ohio State University, Columbus, OH, USA
Interests: polymers; composite materials
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Guest Editor Assistant
School of Chemistry and Chemical Engineering, Nantong University, Nantong 226007, China
Interests: polymer composites; injection molding; coating

Special Issue Information

Dear Colleagues,

Injection molding is the most widely used manufacturing process to produce polymer-based products for various markets including automotives, appliances, electronics and packaging, etc. For either the non-reinforced or the filler reinforced polymer material, the control process variables directly affect the material microstructure and crystallinity, thus affecting the molded part properties and quality.

For large and complex molding parts, such as a car bumper, its tooling is very expensive, and once the tooling is cut, it is non-reversible. Simulation is a powerful method not only to study the effect of different control process variables, but also the locations of gates, as well as the gate opening strategy. Usually, several iterations of flow simulations are conducted before cutting the tooling, which significantly saves the tooling cost for the molders.

This Special Issue includes several papers that study different applications of process simulation in injection molding, serving as a good summary to provide some guidance and insights for polymer researchers, material engineers and process engineers, as well as raw material suppliers, automotive OEMs, etc.

Prof. Dr. Jose Castro
Guest Editor

Dr. Kaiyu Cai
Guest Editor Assistant

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Keywords

  • injection molding
  • polymer
  • flow simulation
  • application

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Published Papers (1 paper)

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Research

19 pages, 4851 KiB  
Article
Utilizing Simulation Software to Develop Injection Molding Process Windows with High-Impact Polystyrene
by Travis O’Leary, Rachmat Mulyana and Jose M. Castro
Polymers 2025, 17(6), 718; https://doi.org/10.3390/polym17060718 (registering DOI) - 8 Mar 2025
Abstract
While design groups have utilized the abilities of injection molding simulation software, its use is often underutilized by process engineers. To expand the application of simulation software to manufacturing groups, this work focuses on developing a methodology to construct injection molding process windows [...] Read more.
While design groups have utilized the abilities of injection molding simulation software, its use is often underutilized by process engineers. To expand the application of simulation software to manufacturing groups, this work focuses on developing a methodology to construct injection molding process windows through the predictions of simulation software. The methodology was developed by testing combinations of controllable process variables in the filling and packing stage of the injection molding process with high-impact polystyrene. Using this method, the process window can be tailored to a manufacturer’s desired product performance measures as well as target a specific defect they are facing. The process windows developed were experimentally validated displaying a successful combination of controllable process variables in the filling and packing stages which resulted in an acceptable part. Additionally, the process window was able to predict the dimensional shrinkage of a part within 1% of the experimentally produced part. This analysis establishes confidence in the software’s ability to aid manufacturing groups to successfully run their operations. Full article
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