In the fiercely competitive aerospace sector, the adoption of cutting-edge technologies such as injection molding process development software can markedly enhance operational efficiency and product quality. A pivotal encounter I had with a company president in Los Angeles illustrates this point distinctly. Initially skeptical about the necessity of my process-development software Nautilus, the president was enlightened after I demonstrated a 16% reduction in cycle time and improved the robustness of their process by adjusting a four-cavity mold they were running.
It is a common pitfall in our industry to aim for molding parts to specifications during the initial run. However, strategic process development focuses on ensuring that the mold itself supports a 'no-tweak,' maintenance-free production fundamental in achieving a robust process. Robustness in injection molding means the ability to consistently produce quality parts without adjustments, regardless of shifts or environmental changes. This is akin to setting a car on cruise control along a wide, straight highway rather than along a treacherous cliffside road.
When formulating a process, the review of the 11+2 injection molding processing parameters plays a crucial role. These parameters, if not optimized, become sources of variation affecting part quality. During the initial phase of my process development, I concentrate solely on finding a Cosmetic Process Window (CPW) for each parameter, which determines if parts can meet cosmetic standards without considering dimensions. Following this phase, a Designed Experiment (DOE) is conducted to refine these parameters further to meet precise dimensional needs, establishing what we call a Dimensional Process Window (DPW).
However, even with a perfectly set CPW, the real challenge lies when the required settings are critical, with almost no margin for error akin to driving on that narrow cliffside road. This scenario necessitates re-evaluations and potential adjustments to either the mold or product specifications based on robust data from DOEs, ensuring a broader and safer operational window the ideal 'wide highway' for ongoing production.
The key takeaway for aerospace injection molding professionals is the significance of leveraging scientific molding principles throughout the entire journey of the plastic pellet, from storage to the final product, emphasizing a balanced integration of all process aspects. By adopting such advanced methodologies, companies can secure a substantial competitive edge through enhanced quality control and operational efficiency.
About the author: Suhas Kulkarni is the founder and president of Fimmtech, San Diego, specializing in Scientific Molding. With decades of expertise, he has contributed significantly to process development in injection molding, training numerous professionals and authoring influential books on the subject.
Leave a Reply