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Table of Content

Preface v

Helmut Potente and Hans-Peter Heim

One-shot Manufacturing: What is Possible with New Molding Technologies 1

James F. Stevenson

Chapter 1: Gas Assisted Injection Molding 15Gas Assist Injection Molding. The North American Legacy 15

Jack Avery

Flow Directions in the Gas Assisted Injection Molding Technology 27

Young Soo Soh and Chan Hong Chung

Gas-assisted Injection Molding: Influence of Processing Conditions and

Material Properties 35

Kurt W Koelling and Ronald C Kaminski

Cover Part as an Application Example for Gas-assisted Injection Molded Parts 43

Michael Hansen

Molded Part Design for the Gas Injection Technique 51

H. Potente and H.-P. HeimDesign Optimization of Gas Channels for an Air Cleaner Assembly Using

CAE Simulations 57

D.M. Gao, A. Garcia-Rejon, G. Salloum and D. Baylis

The Occurrence of Fiber Exposure in Gas Assist Injection Molded Nylon

Composites 65

Shih-Jung Liu and Jer-Haur Chang

Saving Costs and Time by Means of Gas-assisted Powder Injection Molding 73

Christian Hopmann, Walter Michaeli

Gas-assisted Reaction Injection Molding (GRIM): Application of the GasInjection Technology to the Manufacturing of Hollow Polyurethane Parts 79

I. Kleba, E. Haberstroh

Chapter 2: Thin Wall Molding 89Thin Wall Processing of Engineering Resins: Issues and Answers 89

Larry Cosma

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Effects of Processing Conditions and Material Models on the Injection

Pressure and Flow Length in Thinwall Parts 99

A. J. Poslinski

10 Common Pitfalls in Thin-Wall Plastic Part Design 107Timothy A. Palmer

Flow Instabilities in Thin-wall Injection Molding of Thermoplastic Polyurethane 113

Christian D. Smialek, Christopher L. Simpson

Pressure Loss in Thin Wall Moldings 121

John W. Bozzelli, Jim Cardinal, and Bill Fierens

Integrating Thin Wall Molders Needs into Polymer Manufacturing 127

W. G. Todd, H. K. Williams, D. L. Wise

Thinning Injection Molded Computer Walls 133

Lee Hornberger and Ken Lown

Chapter 3: Molding Micro Parts and Micro Structures 143Transcription of Small Surface Structures in Injection Molding an Experimental

Study 143

Uffe R. Arl, Erik M. Kjr

Injection Molding of Sub- m Grating Optical Elements 149

R. Wimberger-Friedl

Process Analysis and Injection Molding of Microstructures 157

Alrun Spennemann and Walter MichaeliSimualtion of the Micro Injection Molding Process 163

Oliver Kemmann, Lutz Weber, Ccile Jeggy, Olivier Magotte, and

Franois Dupret

Chapter 4: Manufacturing of Composites 171Melt Compression Molding (MCM) a One-shot Process for In-mold Lamination

and Compression Molding by Melt Strip Deposition 171

Georg H. Kuhlmann

In-mold Lamination Back Compression Molding 187

Thomas Huber

Analysis and Characterization of Flow Channels during Manufacturing of

Composites by Resin Transfer Molding 193

R. V. Mohan, K. K. Tamma, S. Bickerton, S. G. Advani and D. R. Shires

Optimization of Channel Design in VARTM Processing 209

Roopesh Mathur, Suresh G. Advani and Bruce K. Fink

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Injection Compression Molding. A Low Pressure Process for Manufacturing

Textile-Covered Mouldings 215

Carsten Brockmann, Walter Michaeli

Kurz-Hastings Inmold Decoration 223Roy Bomberger

Chapter 5: Improving Material Properties 229High Impact Strength Reinforced Polyester Engineering Resins for Automotive

Applications 229

Mengshi Lu, Kevin Manning, Suzanne Nelsen, and Steve Leyrer

Control of Internal Stresses in Injection Molded Parts Through the Use of

Vibrational Molding, RHEOMOLDINGSM, Technology 237

Akihisa Kikuchi, Marc Galop, Harold L. Brown, and Alexander BubelExperimental Determination of Optimized Vibration-assisted Injection Molding

Processing Parameters for Atactic Polystyrene 245

Alan M. Tom, Akihisa Kikuchi, and John P. Coulter

Vibrated Gas Assist Molding: Its Benefits in Injection Molding 253

J.P. Ibar

Chapter 6: Mold Making and Plasticisation 259Advances in Stack Molding Technology 259

Vincent Travaglini and Henry RozemaAdvanced Valve Gate Technology for Use in Specialty Injection Molding 267

John Blundy, David Reitan, and Jack Steele

In-mold Labeling for High Speed, Thin Wall Injection Molding 273

Gary Fong

Advances in Fusible Core Technique 281

E. Schmachtenberg and O. Schrder

Processing Glass-filled Polyethylene on a Twin-screw Injection Molding

Extruder 287

David Bigio, Rajath Mudalamane, Yue Huang and Saeid Zerafati

Injection Molding by Direct Compounding 295

Bernd Klotz

Improvement of the Molded Part Quality: Optimization of the Plastification Unit 301

S. Boelinger and W. Michaeli

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Non-return Valve with Distributive and Dispersive Mixing Capability 307

Chris Rauwendaal

Index 313