Microinjection
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This document summarizes Prodintec's microinjection technologies and facilities. It describes how Prodintec identified microtechnologies as a key research area in 2009 and established a new microinjection laboratory. The microinjection process involves plasticizing raw materials, dosing them through an electronic valve, and injecting them into molds under high pressure. Prodintec has a Wittmann-Battenfeld Microsystem 50 machine for microinjection that reduces material residence time at high temperatures. It also has measurement and control systems for precision microinjection including a Zeiss Contura G2 CMM and Leica stereoscopic microscope.
Microinjection
- 2. MICROINJECTION INTRODUCTION Microtechnologies were identified as a key research line for next years by PRODINTEC. Since 2009 there is a new microinjection laboratory working on this field. Micromilling and microinjection were developed jointly, improving their synergies and the potential common research projects.
- 3. MICROINJECTION DESCRIPTION Thermoplastics microinjection is not so different of standard injection. Specific control requirements are needed being the process more complex. The Wittmann-Battenfeld Microsystem 50 equipment perfoms the injection process in three steps. The whole material introduced on the mould have the best conditions for being processed considering short resident times at high temperature.
- 4. MICROINJECTION DESCRIPTION The raw material is plasticized on the screw, it is dosed through the electronic valve and stays at the cavity until the injection piston bring back. When the valve is closed the plastic material flows through the injection channel being introduced into the mould at high pressure and velocity. CAD mould design CAD design Mould Fabrication The injection process depends on the fabrication and optimization of the injection mould. The mould phase is the bottleneck of the microinjection process. It is highly critical the precision during mould fabrication. Experts on molding technologies are required..
- 5. MICROINYECCIÓN ADVANTAGES: • High precision on the injection of thermoplastic, ceramic and metallic pieces. •Three steps injection. Reduction of resident time of materials at high temperature. The degraded material usually generated by conventional injection is eliminated. • Reproducibility and repeatability. • Automatic high production system based on the double mould configuration. Processing and injection process can be simultaneously performed. • Reduction of wastes, material injection optimized. There is a reduction of materials costs per injected unit.
- 6. MICROINJECTION PRODINTEC FACILITIES: The equipment for microinjection is a Wittmann-Battenfeld (Microsystem 50 model) with the following characteristics: Servo electric machine Closing force: 50 Kn Maximum mould size: 190x150x200 mm Maximum distance between plates 300 mm Maximum injection pressure 2.500 bares
- 7. MICROINJECTION PRODINTEC FACILITIES: Maximum injection volume: 1,1 cm3 Screw Ø14 mm Injection piston Ø5 mm Injection process in 3 steps Linear module for collecting pieces Rotary plate Injection in closing area Injection control (UNILOG B4)
- 8. MICROINJECTION EXAMPLES Microchannels and microwalls MIM Calibration parts
- 9. MICROMECHANIZATION MEASUREMENT AND CONTROL SYSTEMS MMC Zeiss model Contura G2 Measurement volume: 1.000x1.600x850 mm Tactile measurement system (synthetic ruby) precision of measurement 0,1 µm uncertainty 1,9 µm en 300 mm Optical measurement system (VISCAN 4x) precision 0,1 µm e uncertainty 10 µm (VDI/VDE 2617) Touch probe VAST XXT TL1 ID Automatic change of touch probes with 7 positions including VISCAN camera Software Calypso CNC Geometry 4.4 ENAC certificate of calibration Cooling room with temperature and moisture control (20º±0,5º) Perfilómeter óptic SOLARIUS model Viking The tool is designed to meet mid range accuracy needs using state of the art sensor technology to generate 3 dimensional surface maps. Viking is a desktop general laser measuring tool consisting of an X/Y 100mm moving axis platform mounted below a laser sensor to provide fast non-contact profiling of a vast variety of engineering surfaces and electronic components. Cromatic sensors WLC2 range 300 µm, resolution 0,012 µm, accuracy 0,06 µm, spot 2,6 µm and WLC4 range 2,5 mm, resolution 0,075 µm, accuracy 0,4 µm, spot 25,6 µm Offset camera integrated with monitor Motorised axes X/Y with a maximun movement range 100 mm each axe. Software for analysis SolarMap 3D Cooling room with temperature and moisture control (20º±0,5º) Microscope estereoscopic Leica model M205A Stereoscopic microscope Leica (M205A model) with the following characteristics: Optic 20,5:1 motorised Zoom 7,8x a 160x Resolution 525 Lp/mm Visual field 29,5 mm a 1,44 mm Lens 1,0x y 2,0x Coaxial Led 5000 CXI Digital camera Leica DFC 420 (5,0 Mpx with Firewire connection) Measurement LAS Vision system 3D LAS
- 10. PRODINTEC Technological Research Center for the Design and Industrial Production EDIFICIO CENTROS TECNOLÓGICOS PARQUE CIENTÍFICO Y TECNOLÓGICO 33203 GIJÓN. ASTURIAS T +34 984 390 060 F +34 984 390 061 www.prodintec.com