Search Results (505)

The main thrust of the study is the need to cut down the time taken for mold changes in plastic injection molding which is fundamental to the productivity and efficiency of the process. The research encompasses Lean Manufacturing, DMAIC, and SMED which are improved using fuzzy logic and AI for rapid changeover optimization on the NEGRI BOSSI 650 machine. A decrease in downtime by 65% and an improvement in the Process Cycle Efficiency by 46.8% followed the identification of bottlenecks, externalizing tasks, and streamlining workflows. AI-driven analysis could make on-the-fly adjustments, which would ensure that resources are better allocated, and thus sustainable performance is maintained. The findings highlight how integrating Lean methods with advanced technologies enhances operational agility and competitiveness, offering a scalable model for continuous improvement in industrial settings. Full article

This study presents a breakthrough in sustainable injection molding by uniquely combining a backpropagation neural network (BPNN) with particle swarm optimization (PSO) to overcome traditional optimization challenges. The BPNN’s exceptional ability to learn complex nonlinear relationships between six key process parameters (including melt temperature and holding pressure) and product quality is amplified by PSO’s intelligent search capability, which efficiently navigates the high-dimensional parameter space. Together, this hybrid approach achieves what neither method could accomplish alone: the BPNN accurately models the intricate process-quality relationships, while PSO rapidly converges on optimal parameter sets that simultaneously meet strict quality targets (66–70 g weight, 3–5 mm thickness) and minimize energy consumption. The significance of this integration is demonstrated through three key outcomes: First, the BPNN-PSO combination reduced optimization time by 40% compared to traditional trial-and-error methods. Second, it achieved remarkable prediction accuracy (RMSE 0.8229 for thickness, 1.5123 for weight) that surpassed standalone BPNN implementations. Third, the method’s efficiency enabled SMEs to achieve CAE-level precision without expensive software, reducing setup costs by approximately 25%. Experimental validation confirmed that the optimized parameters decreased energy use by 28% and material waste by 35% while consistently producing parts within specifications. This research provides manufacturers with a practical, scalable solution that transforms injection molding from an experience-dependent craft to a data-driven science. The BPNN-PSO framework not only delivers superior technical results but does so in a way that is accessible to resource-constrained manufacturers, marking a significant step toward sustainable, intelligent production systems. For SMEs, this framework offers a practical pathway to achieve both economic and environmental sustainability, reducing reliance on resource-intensive CAE tools while cutting production costs by an estimated 22% through waste and energy savings. The study provides a replicable blueprint for implementing data-driven sustainability in injection molding operations without compromising product quality or operational efficiency. Full article

Acoustic tweezers, as advanced micro/nano manipulation tools, play a pivotal role in biomedical engineering, microfluidics, and precision manufacturing. However, piezoelectric-based acoustic tweezers face performance limitations due to multi-physical coupling effects during microfabrication. This study proposes a novel approach using injection molding with embedded electronics (IMEs) technology to fabricate piezoelectric micro-ultrasonic transducers with micron-scale precision, addressing the critical issue of acoustic node displacement caused by thermal–mechanical coupling in injection molding—a problem that impairs wave transmission efficiency and operational stability. To optimize the IME process parameters, a hybrid multi-objective optimization framework integrating NSGA-II and MOPSO is developed, aiming to simultaneously minimize acoustic node displacement, volumetric shrinkage, and residual stress distribution. Key process variables—packing pressure (80–120 MPa), melt temperature (230–280 °C), and packing time (15–30 s)—are analyzed via finite element modeling (FEM) and validated through in situ tie bar elongation measurements. The results show a 27.3% reduction in node displacement amplitude and a 19.6% improvement in wave transmission uniformity compared to conventional methods. This methodology enhances acoustic tweezers’ operational stability and provides a generalizable framework for multi-physics optimization in MEMS manufacturing, laying a foundation for next-generation applications in single-cell manipulation, lab-on-a-chip systems, and nanomaterial assembly. Full article

Biodegradable polymer composites offer promising alternatives to petroleum-based plastics, supporting the principles of a zero waste and circular economy. This study investigates the reinforcing potential of alkali-treated wood flour derived from recycled pine (Pinus brutia Ten.) and poplar (Populus alba L.) waste wooden pallets in poly(lactic acid) (PLA) biocomposites. Wood flour was initially recovered through grinding and screening during recycling, followed by alkali treatment via a green chemistry approach to enhance interfacial bonding with the PLA matrix. The impact of alkali concentration and two fabrication methods—additive manufacturing (AM) and injection molding (IM)—on the properties of developed biocomposite materials was assessed through mechanical, physical, morphological, and thermal analyses. IM samples outperformed AM counterparts, with the IM PLA containing 30 wt% wood flour (alkali-treated with 10% solution) showing the highest mechanical gains: tensile (+71.35%), flexural (+64.74%), and hardness (+2.62%) compared to untreated samples. Moreover, the AM sample with 10 wt% wood flour and 10% alkali treatment showed a 49.37% decrease in water absorption compared to the untreated sample, indicating improved hydrophobicity. Scanning electron microscopy confirmed that alkali treatment reduced void content and enhanced morphological uniformity, while thermal properties remained consistent across fabrication methods. This work introduces a green composite using non-toxic materials and treatments, facilitating eco-friendly production aligned with zero waste and circular economy principles throughout the manufacturing lifecycle. Full article

Resin Transfer Molding (RTM) is a widely used composite manufacturing process where liquid resin is injected into a closed mold filled with a fibrous preform. By applying this process, large pieces with complex shapes can be produced on an industrial scale, presenting excellent properties and quality. A true physical phenomenon occurring in the RTM process, especially when using vegetable fibers, is related to the absorption of resin by the fiber during the infiltration process. The real effect is related to the slowdown in the advance of the fluid flow front, increasing the mold filling time. This phenomenon is little explored in the literature, especially for non-isothermal conditions. In this sense, this paper does a numerical study of the liquid injection process in a closed and heated mold. The proposed mathematical modeling considers the radial, three-dimensional, and transient flow, variable injection pressure, and fluid viscosity, including the effect of liquid fluid absorption by the reinforcement (fiber). Simulations were carried out using Computational Fluid Dynamic tools. The numerical results of the filling time were compared with experimental results, and a good approximation was obtained. Further, the pressure, temperature, velocity, and volumetric fraction fields, as well as the transient history of the fluid front position and injection fluid volumetric flow rate, are presented and analyzed. Full article

This study investigates a hybrid manufacturing approach that combines 3D printing and injection molding to extend the limitations of each individual technique. Injection molding is often limited by high initial tooling costs, long lead times, and restricted geometric flexibility, whereas 3D-printed molds tend to suffer from material degradation, extended cooling times, and lower surface quality. By integrating 3D-printed molds into the injection-molding process, this hybrid method enables the production of complex geometries with improved cost-efficiency. The approach is demonstrated using a range of polymeric materials, including ABS, nylon, and polyurethane foam—each selected to enhance the mechanical and thermal performance of the final products. Finite element method (FEM) analysis was conducted to assess thermal distribution, deformation, and stress during manufacturing. Results indicated that both temperature and stress remained within safe operational limits for 3D-printed materials. An economic analysis revealed substantial cost savings compared to fully 3D-printed components, establishing hybrid manufacturing as a viable and scalable alternative. This method offers broad industrial applicability, delivering enhanced mechanical properties, design flexibility, and reduced production costs. Full article

This study consisted of the injection molding simulation of polycaprolactone (PCL)-based nanocomposites reinforced with multi-walled carbon nanotubes (MWCNTs) for biomedical implant manufacturing. The simulation was additionally supported by experimental validation. The influence of varying MWCNT concentrations (0.5%, 5%, and 10% by weight) on key injection molding parameters, i.e., melt flow behavior, pressure distribution, temperature profiles, and fiber orientation, was analyzed with SolidWorks Plastics software. The results proved the low CNT content (0.5 wt.%) to be endowed with stable filling times, complete mold cavity filling, and minimal frozen regions. Thus, this formulation produced defect-free modular filament sticks suitable for subsequent 3D printing. In contrast, higher CNT loadings (particularly 10 wt.%) led to longer fill times, incomplete cavity filling, and early solidification due to increased melt viscosity and thermal conductivity. Experimental molding trials with the 0.5 wt.% CNT composites confirmed the simulation findings. Following minor adjustments to processing parameters, high-quality, defect-free sticks were produced. Overall, the PCL/MWCNT composites with 0.5 wt.% nanotube content exhibited optimal injection molding performance and functional properties, supporting their application in modular, patient-specific biomedical 3D printing. Full article

This article presents research and a discussion on the proper use of filtration in optical measurements. Measurements were taken using a Werth multisensory machine using a Werth Zoom optical sensor. During optical measurements, the filtration option can be used. The manufacturer defines filters as “Dust”. They allow the machine operator to define the appropriate size depending on the type of inclusions or artifacts created in the production process. They can occur in processes such as punching on presses or production in the injection molding process of plastics. The presented research results and statistical analyses confirm the assumptions regarding the validity of using filters and their values. The use of filters with a higher value significantly affects the obtained results and forces the machine user to make a reasonable choice. Full article

This study investigates the industrial potential of red gypsum (RG), a major by-product of titanium dioxide (TiO₂) production, for the development of thermoplastic polypropylene (PP)-based composites via melt extrusion, targeting agricultural applications. Prior to compounding, RG was thermally treated at approximately 200 °C to remove residual moisture and chemically bound water, resulting in its anhydrous form (CaSO₄). PP/RG composites were then formulated with RG loadings up to 20 wt.%, employing stearic acid (SA) as a compatibilizer. The resulting materials were thoroughly characterized and successfully processed through industrial-scale injection molding up to 250 °C. Morphological and FTIR analyses confirmed the role of SA in enhancing both filler dispersion and interfacial adhesion between RG and the PP matrix. SEM images revealed finer and more uniformly distributed RG particles, resulting in a reduced loss of ductility and elongation at break typically associated with filler addition. Specifically, the Young’s Modulus increased from 1.62 GPa (neat PP) up to 3.21 GPa with 20 wt.% RG and 0.6 wt.% SA. The addition of 0.6 wt.% SA also helped limit the reduction in stress at break from 46.68 MPa (neat PP) to 34.05 MPa and similarly mitigated the decrease in Charpy impact energy, which declined slightly from 2.66 kJ/m² (neat PP) to 2.24 kJ/m² for composites containing 20 wt.% RG. Preliminary phytotoxicity was assessed using germination tests on Lepidium sativum L. seeds. Eluates from both untreated and SA-treated RG powders resulted in germination indices below 80%, indicating phytotoxicity likely due to high sulfate ion concentrations. In contrast, eluates from composite pellets exhibited germination indices equal to or exceeding 100%, demonstrating the absence of phytotoxic effects. These results highlight the suitability of the developed composites for applications in floriculture and horticulture. The optimized composite pellets were successfully processed via injection molding to manufacture plant pots, which exhibited a dark brown coloration, confirming the effective pigmenting function of RG. These results demonstrate the potential of red gypsum to serve both as a functional filler and pigment in PP composites, providing a sustainable alternative to iron oxide pigments and promoting the valorization of industrial waste through resource recovery. Full article

Polymers are essential materials in the fabrication of partial and complete dentures, where their mechanical properties directly impact durability, comfort, and clinical performance. This study examines the influence of different manufacturing temperatures on the surface hardness of polymeric materials used in dental applications. A total of 60 experimental samples with a rectangular shape of Vertex ThermoSens polymer (Vertex Dental, 3D Systems, Soesterberg, The Netherlands) were fabricated through injection molding at 280 °C and 300 °C and analyzed over time to assess changes in their properties. Hardness measurements, conducted using the EQUOTIP Shore D hardness tester (Proceq SA, Schwerzenbach, Canton of Zürich, Switzerland), indicated increased hardness over time, with higher values observed in samples fabricated at 300 °C. A two-way ANOVA was performed to evaluate the statistical significance of temperature and time on hardness, revealing a significant effect (F = 14.73, p = 0.0185). These findings suggest that processing polymers at elevated temperatures improves surface hardness, significant for denture longevity and patient comfort. Increased hardness contributes to greater wear resistance. Optimizing polymer manufacturing conditions can thus lead to improved clinical outcomes, ensuring more durable and biocompatible dental prostheses. Full article

In this paper, we develop technology to improve the stability and quality of boat equipment manufacturing through vacuum injection process fusion to increase the safety of boats. Safe mold design and fabrication are carried out to determine the resin flow rate and water flow rate of a boat, and the performance of vacuum maintenance work is guaranteed through the tensile and compressive strength of the manufactured hull and deck. When manufacturing the boat air mechanism (Aerostat), the adhesion between equipment materials and the deformation of the joints are very important factors for safety. Due to the nature of equipment manufacturing, process fusion to minimize manual process minimizes deformation after manufacturing through accurate manufacturing ratio. Accordingly, it is possible to accurately control the mixing ratio of resin and hardener as optimal conditions for boat drying and securing safety, and to convert optimal information into a database by analyzing working conditions over time such as resin flow rate and flow rate, thereby improving durability and quality. Through this, it is expected that production efficiency and safety design will be improved by enabling efficient production process management with a small number of personnel. Full article

Metal injection molding (MIM) is a current technology used to produce products with complex shapes. Despite the accumulated worldwide experience in using this technology, manufacturers sometimes fail to launch new products of proper quality. Often, this is because defects can occur at the casting stage, the prevention of which is impossible through the use of standard design and technological solutions of molds design and the experimental selection of technological modes. This study aimed to analyze the causes of such defects in the green part and optimize the mold design to ensure defect-free casting, which was impossible for the manufacturer using standard solutions. The core method used in this study was simulation modeling of the casting process. A hypotheses were selected, and an analysis of the causes of defect occurrence in casting was conducted. Simulation modeling proved that defect occurrence was due to the formation of a free melt jet and subsequent air capture by this jet. Based on modeling, different gating and feeding system designs were analyzed, which made it possible to choose a variant that provided the uniform filling of gating cavities without forming jet flows and defects. The novelty of this study lies in its optimization of the mold design to prevent free melt jetting and similar defects in other MIM products by modeling feedstock molding processes. The presented results can help enrich the knowledge base of the mold design for MIM and ensure defect-free production. Full article

The agricultural sector faces growing pressure to enhance productivity and sustainability, prompting innovation in machinery design. Traditional materials such as steel still dominate but are a cause of increased weight, soil compaction, increased fuel consumption, and corrosion. Composite materials—and, more specifically, fiber-reinforced polymers (FRPs)—offer appealing alternatives due to their high specific strength and stiffness, corrosion resistance, and design flexibility. Meanwhile, increasing environmental awareness has triggered interest in biocomposites, which contain natural fibers (e.g., flax, hemp, straw) and/or bio-based resins (e.g., PLA, biopolyesters), aligned with circular economy principles. This review offers a comprehensive overview of synthetic composites and biocomposites for agricultural machinery and equipment (AME). It briefly presents their fundamental constituents—fibers, matrices, and fillers—and recapitulates relevant mechanical and environmental properties. Key manufacturing processes such as hand lay-up, compression molding, resin transfer molding (RTM), pultrusion, and injection molding are discussed in terms of their applicability, benefits, and limits for the manufacture of AME. Current applications in tractors, sprayers, harvesters, and planters are covered in the article, with advantages such as lightweighting, corrosion resistance, flexibility and sustainability. Challenges are also reviewed, including the cost, repairability of damage, and end-of-life (EoL) issues for composites and the moisture sensitivity, performance variation, and standardization for biocomposites. Finally, principal research needs are outlined, including material development, long-term performance testing, sustainable and scalable production, recycling, and the development of industry-specific standards. This synthesis is a practical guide for researchers, engineers, and manufacturers who want to introduce innovative material solutions for more efficient, longer lasting, and more sustainable agricultural machinery. Full article

Three-dimensional (3D) printing has become a promising alternative to conventional methods in plastic part production, particularly for customized or low-volume applications such as toys. This study compares toy components produced by Fused Deposition Modeling (FDM) using polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS) filaments and those produced by traditional injection molding using ABS pellets. Unlike in many previous studies based on standardized test samples, a real toy part was evaluated in terms of compressive strength, dimensional accuracy, surface quality, and cost. Experimental results revealed that ABS parts produced by injection molding exhibited the highest compressive strength (3.93 kN), followed by PLA-FDM (2.97 kN) and ABS-FDM (0.95 kN). Similarly, injection-molded parts showed superior surface smoothness and dimensional accuracy. Cost analysis indicated that injection molding is economically viable only when production exceeds 735 pieces, while FDM becomes more attractive for smaller batches due to its low initial cost. A multi-criteria decision-making analysis using the TOPSIS method was conducted to integrate technical and economic factors. Results showed that injection molding is preferable for mass production, whereas PLA-FDM is more suitable for low-quantity, cost-sensitive scenarios. Full article

In this paper, we are looking for the answer to the following question: what geometric deviations do polymer gears made by 3D printing have from the theoretical geometry? From a practical point of view, the question is whether the currently installed injection-molded gear can be replaced by a 3D-printed gear. Thus, the measurements are also carried out on the sample gear and the comparison is made with this data as well. Knowing the data of the existing gear wheel, the CAD model was created, and based on this, samples of the gear were printed using various 3D printing machines. The printed gears were then subjected to geometrical analysis. During the inspection, we performed the measurement of the chordal thickness of the gear wheel using a gear tool caliper, instead of pin measurement and span measurement using a special micrometer, and 3D scanning and analysis. A surface roughness measurement was carried out as well. By conducting measurements on the injection-molded and 3D-printed samples, this research seeks to evaluate the reliability and limitations of the 3D-printed gears, providing insights into their industrial use. This study aims to determine whether 3D printing technologies can produce gears with sufficient accuracy and surface quality for practical applications. Based on the conducted analysis, general conclusions were drawn regarding the potential applicability of the 3D-printed gears. The experimental results indicate notable differences in dimensional accuracy between gears manufactured using Fused Deposition Modeling (FDM) and Selective Laser Sintering (SLS). In terms of chordal thickness measurements, FDM gears exhibited a mean relative error of 1.96 mm, whereas SLS gears showed a significantly higher average deviation of 5.64 mm. For the pin measurement, the relative error averaged 0.193 mm in the case of FDM gears, compared to 0.616 mm for SLS gears. Similarly, the span over four teeth measurements resulted in an average deviation of 0.153 mm for FDM gears, while SLS gears demonstrated a markedly higher mean error of 0.773 mm. With regard to surface roughness, it can be concluded that SLS-manufactured gears exhibit superior performance compared to FDM gears, with an average Ra value of 2.65 µm versus 9.28 µm, although their surface quality remains inferior to that of the injection-molded gear. In light of the higher relative errors observed in SLS gears compared to FDM gears, the dimensions of the theoretical model should be refined to improve the manufacturing accuracy of SLS-produced gears. Full article