Future Development and Technological Innovation of Micro Injection Molding Machines
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With the rapid advancement of science and technology, products are continuously trending toward miniaturization. This has led to the emergence of MEMS (Micro-Electro-Mechanical Systems) technology, which is essential for meeting industrial demands in the 21st century. In 2002, the global market for MEMS reached a production value of $45 billion, with its applications spanning fields such as optoelectronics, image transmission, biomedical treatment, data storage, and precision machinery. To produce practical micro-components, various emerging manufacturing technologies have been developed, including LIGA (Lithography, Electroforming, and Molding), UV etching, EDM (Electrical Discharge Machining), micro-injection molding, precision grinding, and cutting. Among these, micro-injection molding has become a key area of research due to its ability to enable low-cost, high-volume production of parts with intricate microstructures.
The quality of micro-injection molded parts is measured in milligrams, while their geometry is on the micrometer scale. The technology began developing in the late 1980s and is now considered an advanced manufacturing method. Compared to traditional injection molding, it requires different materials, processes, and equipment. Many established injection molding techniques are not suitable for micro-scale production, making it necessary to thoroughly study and develop theoretical and practical approaches specific to micro-injection molding.
### 1. Special Requirements for Micro Injection Molding Machines
In the early stages of micro-injection molding development, there were no dedicated machines for producing micro-parts. Instead, traditional large or medium-sized injection molding machines were used with multi-cavity molds, which posed challenges in mold flow balance and part quality control. Therefore, specialized machines were needed to meet the demands of miniaturization and high precision.
Compared to conventional systems, micro-injection molding machines require:
- **High Injection Rate**: Due to the small size of micro-parts, the injection process must be fast to prevent premature solidification. While standard hydraulic machines operate at around 200 mm/s, electric servo-driven machines can reach 600 mm/s. However, micro-injection molding often requires speeds above 800 mm/s to reduce polymer melt viscosity through shear thinning, ensuring proper cavity filling.
- **Precise Injection Volume Measurement**: Micro-parts weigh only a few milligrams, requiring precise control of the injection volume. Traditional screw-based systems lack the accuracy needed for micro-level control, leading to inconsistencies in part quality.
- **Fast Reaction Capability**: The small injection volume necessitates quick response from the machine’s drive system to achieve high pressure instantly, ensuring accurate and consistent molding.
### 2. Classification of Micro Injection Molding Machines
To address the limitations of traditional machines, companies like Nissei, Dr. Boy, Battenfeld, MCP, Babyplast, and Takahashi have developed specialized micro-injection molding machines with clamping forces typically under 15 tons. These machines can be classified by drive mode and design of the plasticizing and injection units.
#### 2.1 Screw Type
Screw-type machines use a single screw for plasticizing, metering, and injection. They are simple and easy to control but suffer from poor injection volume accuracy due to the anti-backflow ring. Examples include the Dr. Boy 12A and Nissei HM7-DENKEY.
#### 2.2 Plunger Type
Plunger-type machines use a single or dual plunger for injection. They offer better accuracy than screw types but have limited plasticizing capacity and mixing performance, resulting in lower-quality parts.
#### 2.3 Screw-Plunger Hybrid
Hybrid machines combine a screw for plasticizing and a plunger for precise injection. They offer improved control and quality, though their complex structure increases maintenance requirements. Models like MCP 12/90HSP and Sodick TR18S are widely used.
#### 2.4 Other Special Forms
Some machines, like Ettlinger’s coaxial screw-plunger model, integrate hot runner systems for runner-free molding, reducing material waste and cycle time.
### 3. Development Trends
As micro-injection molding evolves, several challenges remain. These include improving drive systems for higher precision and speed, exploring new plasticizing methods like ultrasonic or laser-assisted techniques, and enhancing product testing capabilities. Additionally, the integration of intelligent and networked systems is becoming increasingly important for real-time monitoring, remote control, and automation.
### 4. Conclusions and Prospects
Despite its relatively short history, micro-injection molding holds great potential for future growth. It supports the development of fine manufacturing and microstructured components, which are critical for industries like MEMS and CAD/CAE/CAM. As demand increases, so will the need for more advanced, efficient, and intelligent micro-injection molding machines. Continued research into materials, processes, and control systems will ensure this technology remains at the forefront of modern manufacturing.
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