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Advances in Injection Molding: Process, Materials and Applications, 2nd Edition
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Advances in Injection Molding: Process, Materials and Applications, 2nd Edition

A special issue of Journal of Manufacturing and Materials Processing (ISSN 2504-4494).

Deadline for manuscript submissions: 31 July 2026 | Viewed by 5547

Special Issue Editors

Dr. Rossella Surace

E-Mail Website
Guest Editor
Institute of Intelligent Industrial Technologies and Systems for Advanced Manufacturing, National Research Council (STIIMA-CNR), Bari, Italy
Interests: injection molding; micro manufacturing; polymer properties and processing; composites; polymeric foams; additive manufacturing
Special Issues, Collections and Topics in MDPI journals
Dr. Vincenzo Bellantone

E-Mail Website
Guest Editor
Institute of Intelligent Industrial Technologies and Systems for Advanced Manufacturing, National Research Council (STIIMA-CNR), Bari, Italy
Interests: injection molding; rheology; surface properties; metrological characterization; FEM simulation
Special Issues, Collections and Topics in MDPI journals
Dr. Irene Fassi

E-Mail Website
Guest Editor
Institute of Intelligent Industrial Technologies and Systems for Advanced Manufacturing, National Research Council (STIIMA-CNR), 13900 Bari, Italy
Interests: micro manufacturing; micro robotics; micro assembly; micro EDM; micro injection molding
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

From the perspectives of engineers, physicists, researchers, and scientists, we intend to analyze and discuss different modern perspectives on materials processing. The high potential of enhancing a material through processing (thermal or mechanical forming, machining, joining, welding, laser processing, plasma processing, micro- and nano-processing) makes standard materials suitable for more applications. Actual activity in this field presents a few problems connected to obtaining and processing metallic alloys, the modification of surface states, and the characterization, modeling, and simulation of prototyping technologies. Based on the multiple possibilities of applying alloys with well-established production technologies by modifying their properties through various processing methods, this Special Issue is dedicated to the results obtained through various thermo-mechanical processes, specialized treatments, sintering of materials obtained through 3D printing or other processing processes implemented at the laboratory or industrial level.

This Special Issue of the Journal of Manufacturing and Materials Processing will focus on the most recent advances in obtaining and processing materials used in the industrial, automotive, chemical, or medical fields with improved performances.

Dr. Rossella Surace
Dr. Vincenzo Bellantone
Dr. Irene Fassi
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 250 words) can be sent to the Editorial Office for assessment.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Journal of Manufacturing and Materials Processing is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 1800 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • injection molding
  • micro injection molding
  • materials/process interactions
  • structure/properties relationships
  • quality control

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Related Special Issue

Published Papers (6 papers)

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Research

22 pages, 8194 KB  
Article
Thermal and Flow Effects of Limescale on the Cooling of Slender Injection Molding Cores: A Numerical Study
by Andrea Gruber, Mayank Ambasana, Jeremy Payne, Aravind Rammohan, David O. Kazmer, Stephen P. Johnston and Davide Masato
J. Manuf. Mater. Process. 2026, 10(4), 130; https://doi.org/10.3390/jmmp10040130 - 14 Apr 2026
Viewed by 336
Abstract
Different strategies have been proposed to optimize injection mold cooling to reduce cycle time and improve efficiency. While recent research has focused on the design of additively manufactured conformal cooling inserts, the impact of mold maintenance conditions on cooling performance has received limited [...] Read more.
Different strategies have been proposed to optimize injection mold cooling to reduce cycle time and improve efficiency. While recent research has focused on the design of additively manufactured conformal cooling inserts, the impact of mold maintenance conditions on cooling performance has received limited attention, particularly regarding the formation of limescale. This work presents a numerical modeling approach to quantify the combined effects of thermal resistance and hydraulic restriction caused by limescale accumulation in high-aspect-ratio cooling channels used in slender mold cores. An integrated thermal-fluid analysis is employed to evaluate coolant flow behavior and heat-transfer performance and to assess their coupled influence on cooling efficiency and part dimensional stability. The results show that, in slender cooling channels, even thin limescale deposits can significantly reduce cooling performance, with hydraulic restriction emerging as the dominant mechanism under the investigated conditions due to the reduced effective flow area. Design strategies that reduce effective frictional length and mitigate limescale deposition reduced part temperature by approximately 10 °C and shortened cooling time by about 17%. Further optimization of coolant flow conditions yielded an additional 65% reduction in cooling time. These findings highlight the importance of integrating cooling design with preventive maintenance to achieve robust injection molding performance. Full article
(This article belongs to the Special Issue Advances in Injection Molding: Process, Materials and Applications, 2nd Edition)
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17 pages, 3566 KB  
Article
Integrated Optimization for Reducing Injection Molding Defects in Charcoal Canisters
by Mohsen Hedayati-Dezfooli and Mehdi Moayyedian
J. Manuf. Mater. Process. 2026, 10(4), 114; https://doi.org/10.3390/jmmp10040114 - 27 Mar 2026
Viewed by 627
Abstract
This study presents an integrated optimization framework that combines the Design of Experiments (DOE) approach with Machine Learning (ML) techniques to minimize defects in the injection molding of Fuel Vapor Charcoal Canisters. The research focuses on five critical process parameters—melt temperature, mold temperature, [...] Read more.
This study presents an integrated optimization framework that combines the Design of Experiments (DOE) approach with Machine Learning (ML) techniques to minimize defects in the injection molding of Fuel Vapor Charcoal Canisters. The research focuses on five critical process parameters—melt temperature, mold temperature, filling time, pressure holding time, and pure cooling time—whose combined influence on major molding defects (warpage, shrinkage, shear stress, residual stress, and short shots) was systematically investigated. A Taguchi L25 orthogonal array was employed to structure the experiments and identify the optimal parameter levels through signal-to-noise (S/N) ratio analysis using the “smaller-the-better” quality criterion. The Taguchi results revealed that pressure holding time was the most influential factor, followed by mold temperature and melt temperature. Simulation results from SolidWorks Plastics confirmed the reduction in major defects under the optimized settings. To further validate and generalize the DOE findings, a Random Forest regression model was trained on the same dataset to capture nonlinear interactions between parameters. The model achieved an average RMSE of 2.451 ± 0.591 in five-fold cross-validation, demonstrating strong predictive accuracy. Feature importance analysis indicated that pressure holding time accounted for approximately 77.5% of the variance in the defect index, reaffirming its dominant role. A 3D response surface of the global parameter space (mold temperature vs. pressure holding time) revealed a distinct minimum defect region, consistent with the DOE-optimized settings. The Taguchi analysis identified the optimal parameter settings as Melt Temperature at Level 2, Mould Temperature at Level 3, Filling Time at Level 4, Pressure Holding Time at Level 5, and Pure Cooling Time at Level 4, which collectively produced the highest S/N ratios and the lowest overall defect index. The overall discrepancy between DOE and ML predictions was only 12.5%, confirming methodological consistency. The integration of DOE and ML not only enhances parameter interpretability and defect prediction accuracy but also provides a scalable, data-driven approach for intelligent process control and quality assurance in automotive injection molding. Full article
(This article belongs to the Special Issue Advances in Injection Molding: Process, Materials and Applications, 2nd Edition)
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34 pages, 7284 KB  
Article
Wire Directed Energy Deposition Additive Manufacturing: Enabling On-Demand Medical Device Injection Mold Repurposing in Pandemic and Healthcare Supply Challenges
by Leonidas Gargalis, Evangelia K. Karaxi and Elias P. Koumoulos
J. Manuf. Mater. Process. 2026, 10(2), 63; https://doi.org/10.3390/jmmp10020063 - 12 Feb 2026
Viewed by 992
Abstract
The COVID-19 pandemic critically emphasized the need for rapid, flexible, and decentralized manufacturing solutions to support the urgent demand for essential medical equipment, such as oximeters. Metal wire directed energy deposition—w-DED, also known as w-LMD (wire laser metal deposition)—combines the benefits of high [...] Read more.
The COVID-19 pandemic critically emphasized the need for rapid, flexible, and decentralized manufacturing solutions to support the urgent demand for essential medical equipment, such as oximeters. Metal wire directed energy deposition—w-DED, also known as w-LMD (wire laser metal deposition)—combines the benefits of high material utilization, increased printing speed, and reduced waste, making it an attractive alternative to traditional powder-based processes, especially under time-sensitive and resource-constrained conditions. This work presents a case study focusing on the design and fabrication of injection molds for oximeter casings using metal-wire-based DED. Martensitic stainless steel AISI-420 wire was employed as feedstock and processed via laser wire additive manufacturing to produce a robust, near-net-shape mold suitable for plastic injection molding. The material was selected due to good corrosion and wear resistance. However, poor ductility and toughness, together with AM-induced anisotropy, were the main challenges to address. Therefore, a multi-step methodology was defined to study the effect of different process parameters, which was validated through printing trials, and the optimum process parameter set was identified. The process enabled the rapid construction of intricate mold geometries, minimizing lead times and allowing for quick design iterations. Microstructural and physical properties such as microhardness of the as-built molds were thoroughly characterized. This case study not only illustrates the technical feasibility of producing functional injection molds via metal w-DED but also outlines its role as a resilient manufacturing pathway, capable of meeting emergent healthcare needs and supporting broader industrial applications in a post-pandemic context. Full article
(This article belongs to the Special Issue Advances in Injection Molding: Process, Materials and Applications, 2nd Edition)
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18 pages, 4286 KB  
Article
Development of an Automated CAD Framework for Fully Parametric Design of Injection Molds
by Alexandros-Stavros Toumanidis, Savvas Koltsakidis and Dimitrios Tzetzis
J. Manuf. Mater. Process. 2026, 10(2), 59; https://doi.org/10.3390/jmmp10020059 - 9 Feb 2026
Viewed by 1029
Abstract
Injection mold design is a repetitive and time-consuming process with common individual tasks related to each other. This study presents the development of an automatic computer-aided design (CAD) tool for basic injection molds with complete modeling and no other interaction by the user [...] Read more.
Injection mold design is a repetitive and time-consuming process with common individual tasks related to each other. This study presents the development of an automatic computer-aided design (CAD) tool for basic injection molds with complete modeling and no other interaction by the user after inserting the part, built on the SolidWorks Application Programming Interface 2022 (API) and Visual Basic for Applications 7.1 2012(VBA). The tool combines user input forms and supplier catalog data as inputs in an algorithm to automatically generate mold structures, cavity blocks, runner system, ejection system and straight drilled cooling channels without further manual modeling. Three case studies with one-, two-, and four-cavity molds demonstrate the approach. The results show that complete mold assemblies can be produced in less than 10 min rather than hours while maintaining standard component dimensions. Although the present version applies to rule-based geometric placement rather than thermal or injection process optimization, it provides a framework for future integration of more complex mold structures and functions such as slides, hot runner system, unscrewing geometries, conformal cooling, heat-transfer-based design, family molds and machine selection. This work demonstrates how API-driven automation can reduce design time, standardize layouts, and lay the groundwork for next-generation injection mold development. Full article
(This article belongs to the Special Issue Advances in Injection Molding: Process, Materials and Applications, 2nd Edition)
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20 pages, 2491 KB  
Article
The Development and Validation of Equipment for Determining Friction and Adhesion Coefficients Under Conditions Comparable to the Injection Moulding Process
by Ângela R. Rodrigues, Mário S. Correia and António J. Pontes
J. Manuf. Mater. Process. 2026, 10(2), 45; https://doi.org/10.3390/jmmp10020045 - 27 Jan 2026
Viewed by 579
Abstract
Despite extensive research, predicting ejection forces during the injection moulding process remains challenging due to the complex calculation of the coefficient of friction. This coefficient comprises various components that are difficult to isolate, complicating independent predictions. Consequently, using literature-documented coefficient of friction for [...] Read more.
Despite extensive research, predicting ejection forces during the injection moulding process remains challenging due to the complex calculation of the coefficient of friction. This coefficient comprises various components that are difficult to isolate, complicating independent predictions. Consequently, using literature-documented coefficient of friction for different material contacts often leads to discrepancies between the experimental data and the predictive models of ejection forces. The adhesion component is a particularly problematic aspect, and is frequently excluded from analyses due to the difficulties associated with measuring it directly. This study aims to present the development of a tool designed to measure both the friction and adhesion forces under conditions that replicate those of the injection moulding process. The measured values were then used to calculate the corresponding coefficients: the static coefficient of friction (COF) and the coefficient of adhesion (COA). The conducted measurements identified the most influential factors in both coefficient values using a Design of Experiments (DoE), revealing that replication temperature was the factor promoting the highest variation across all the tested polymers. Full article
(This article belongs to the Special Issue Advances in Injection Molding: Process, Materials and Applications, 2nd Edition)
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15 pages, 3267 KB  
Article
Injection Performance of UHMWPE in Micro-Discs for Prosthetic Applications Using SLA Molds
by Rossella Surace, Francesco Modica, Vito Basile, Vincenzo Bellantone and Irene Fassi
J. Manuf. Mater. Process. 2025, 9(9), 318; https://doi.org/10.3390/jmmp9090318 - 18 Sep 2025
Viewed by 1283
Abstract
Ultra-high molecular weight polyethylene (UHMWPE) is widely used in orthopedic and prosthetic applications due to its excellent wear resistance and biocompatibility. However, its high molecular weight presents significant challenges in terms of processing and formability, particularly at the micro scale. This study investigates [...] Read more.
Ultra-high molecular weight polyethylene (UHMWPE) is widely used in orthopedic and prosthetic applications due to its excellent wear resistance and biocompatibility. However, its high molecular weight presents significant challenges in terms of processing and formability, particularly at the micro scale. This study investigates the flowability characteristics of a new melt-processable UHMWPE in micro-disc geometries to evaluate its suitability for advanced prosthetic applications. Micro-injection molding experiments assessed the material’s behavior under various thermal conditions. The influence of parameters such as temperature, pressure, and disc dimensions has direct effects on the flow behavior of UHMWPE and was analyzed by simulation and experiments. Results indicate that while UHMWPE exhibits limited flow under conventional conditions, optimized processing parameters can enhance discs’ formability without compromising the material’s structural integrity, avoiding defects. These findings provide critical insights for the microfabrication of UHMWPE thin components in next-generation prosthetic devices, enabling improved design precision and functional performance. Full article
(This article belongs to the Special Issue Advances in Injection Molding: Process, Materials and Applications, 2nd Edition)
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