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 evolving toward miniaturization. This trend has driven the development of MEMS (Micro-Electro-Mechanical Systems) technology, which is essential for various industries in the 21st century. In 2002, the global market for this field reached $45 billion, with its main applications spanning photoelectric communication, image transmission, biomedical treatment, information storage, and precision machinery. To produce practical micro-components, a variety of emerging manufacturing technologies have emerged, including LIGA (Lithography, Electroforming, and Demolding), UV etching, EDM (Electrical Discharge Machining), micro-injection molding, and precision grinding and cutting. Among these, micro-injection molding has become a major focus due to its ability to enable low-cost mass production of components with precise microstructures.
The quality of micro-injection molded parts is measured in milligrams, while their geometric features are in the micrometer range. The technology began developing in the late 1980s as an advanced manufacturing method. Compared to traditional injection molding, it demands different materials, processes, and equipment. Many established injection molding techniques are not suitable for micro-scale production, making it necessary to conduct thorough theoretical and practical research on the technical characteristics of the micro-injection molding process.
### Special Requirements for Micro Injection Molding Machines
Initially, there were no dedicated machines for producing micro-parts. Instead, conventional medium or large injection molding machines were often used with multi-cavity molds, leading to challenges in flow balance and part quality control. Therefore, specialized machines are required to meet the high-precision and miniaturized demands of micro-parts. Compared to traditional systems, micro-injection molding machines must satisfy several key requirements:
1. **High Injection Rate**: Micro-parts require fast injection speeds to prevent material solidification. While hydraulic machines typically reach 200 mm/s and electric ones up to 600 mm/s, micro-injection molding often needs over 800 mm/s. High-speed injection reduces melt viscosity via shear thinning, ensuring proper cavity filling.
2. **Precision Injection Volume Measurement**: Since micro-parts weigh only a few milligrams, the machine must measure injection volumes precisely at the milligram level, with screw stroke accuracy down to micrometers. Traditional systems struggle with such precision, affecting part quality.
3. **Rapid Reaction Capability**: Due to the small injection volume, the machine must respond quickly to ensure instant pressure application, maintaining consistent performance.
### Classification of Micro Injection Molding Machines
To address the limitations of conventional machines, companies like Nissei, Dr. Boy, Battenfeld, and others developed specialized micro-injection molding machines with clamping forces under 15 tons. These machines can be classified by drive mode—hydraulic/pneumatic, all-electric, or hybrid—and by design of the plasticizing and injection units, such as screw, plunger, or hybrid types.
#### Screw Type
These machines use a single screw for plasticization, metering, and injection. They are simple to control but suffer from poor injection volume accuracy due to anti-backflow rings. Examples include the Dr. Boy 12A and Nissei HM7-DENKEY.
#### Plunger Type
Plunger-based machines offer higher injection precision but have limited plasticizing capacity and mixing performance, leading to lower-quality results. Models like Babyplast 6/10 and Rabbit 2/3 are commonly used.
#### Screw-Plunger Hybrid
This type combines the advantages of both systems. A screw handles plasticization, while a plunger ensures precise metering and injection. Two-stage and three-stage models are available, such as MCP’s 12/90HSP and Battenfeld’s Microsystem 50.
#### Other Special Forms
Some machines, like Ettlinger’s coaxial screw/plunger model, integrate hot runner systems for runner-free molds, improving efficiency and reducing cycle time.
### Development Trends
Micro-injection molding machines continue to evolve, offering new possibilities in micro-structure manufacturing. However, challenges remain in areas such as drive systems, plasticizing methods, material compatibility, testing capabilities, and intelligent automation. Future developments may focus on improving precision, efficiency, and integration with computer systems.
### Conclusion and Outlook
Though still in its early stages, micro-injection molding holds significant potential for advancing manufacturing. As countries invest in MEMS and fine CAD/CAE/CAM products, the demand for micro-injection molding machines will grow. Continued research into driving mechanisms, plasticizing methods, and intelligent systems will shape the future of this promising technology.
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