Experimental Development of an Injection Molding Process Window

Injection molding is one of the most common and effective manufacturing processes used to produce plastic products and impacts industries around the world. However, injection molding is a complex process that requires careful consideration of several key control variables. These variables and how they are utilized greatly affect the resulting parts of any molding operation. The bounds of the acceptable values of each control process variable or CPV must be analyzed and delimited to ensure manufacturing success and produce injected molded parts efficiently and effectively. One such method in which the key CPV of an injection molding operation can be delimited is through the development of a process window. Once developed, operating CPV at values inside the boundaries of the window or region will allow for the consistent production of parts that comply with the desired performance measures (PM), promoting a stable manufacturing process. This work proposes a method to experimentally develop process windows and illustrates the methodology with a specific molding operation.