Table of Contents

Preface
Helmut Potente and Hans-Peter Heim
One-shot Manufacturing: What is Possible with New Molding Technologies
James F. Stevenson

v
1

Chapter 1: Gas Assisted Injection Molding

15

Gas Assist Injection Molding. The North American Legacy

Jack Avery
Flow Directions in the Gas Assisted Injection Molding Technology
Young Soo Soh and Chan Hong Chung
Gas-assisted Injection Molding: Influence of Processing Conditions and
Material Properties
Kurt W Koelling and Ronald C Kaminski
Cover Part as an Application Example for Gas-assisted Injection Molded Parts
Michael Hansen
Molded Part Design for the Gas Injection Technique
H. Potente and H.-P. Heim
Design Optimization of Gas Channels for an Air Cleaner Assembly Using
CAE Simulations
D.M. Gao, A. Garcia-Rejon, G. Salloum and D. Baylis
The Occurrence of Fiber Exposure in Gas Assist Injection Molded Nylon
Composites
Shih-Jung Liu and Jer-Haur Chang
Saving Costs and Time by Means of Gas-assisted Powder Injection Molding
Christian Hopmann, Walter Michaeli
Gas-assisted Reaction Injection Molding (GRIM): Application of the Gas
Injection Technology to the Manufacturing of Hollow Polyurethane Parts
I. Kleba, E. Haberstroh

15
27

35
43
51

57

65
73

79

Chapter 2: Thin Wall Molding

89

Thin Wall Processing of Engineering Resins: Issues and Answers

Larry Cosma

89

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Table of Contents

Effects of Processing Conditions and Material Models on the Injection

Pressure and Flow Length in Thinwall Parts
A. J. Poslinski
10 Common Pitfalls in Thin-Wall Plastic Part Design
Timothy A. Palmer
Flow Instabilities in Thin-wall Injection Molding of Thermoplastic Polyurethane
Christian D. Smialek, Christopher L. Simpson
Pressure Loss in Thin Wall Moldings
John W. Bozzelli, Jim Cardinal, and Bill Fierens
Integrating Thin Wall Molders Needs into Polymer Manufacturing
W. G. Todd, H. K. Williams, D. L. Wise
Thinning Injection Molded Computer Walls
Lee Hornberger and Ken Lown

Chapter 3: Molding Micro Parts and Micro Structures

99
107
113
121
127
133

143

Transcription of Small Surface Structures in Injection Molding an Experimental

Study
143
Uffe R. Arl, Erik M. Kjr
Injection Molding of Sub- m Grating Optical Elements
149
R. Wimberger-Friedl
Process Analysis and Injection Molding of Microstructures
157
Alrun Spennemann and Walter Michaeli
Simualtion of the Micro Injection Molding Process
163
Oliver Kemmann, Lutz Weber, Ccile Jeggy, Olivier Magotte, and
Franois Dupret

Chapter 4: Manufacturing of Composites

Melt Compression Molding (MCM) a One-shot Process for In-mold Lamination
and Compression Molding by Melt Strip Deposition
Georg H. Kuhlmann
In-mold Lamination Back Compression Molding
Thomas Huber
Analysis and Characterization of Flow Channels during Manufacturing of
Composites by Resin Transfer Molding
R. V. Mohan, K. K. Tamma, S. Bickerton, S. G. Advani and D. R. Shires
Optimization of Channel Design in VARTM Processing
Roopesh Mathur, Suresh G. Advani and Bruce K. Fink

171
171
187

193
209

Table of Contents

Injection Compression Molding. A Low Pressure Process for Manufacturing

Textile-Covered Mouldings
Carsten Brockmann, Walter Michaeli
Kurz-Hastings Inmold Decoration
Roy Bomberger

Chapter 5: Improving Material Properties

High Impact Strength Reinforced Polyester Engineering Resins for Automotive
Applications
Mengshi Lu, Kevin Manning, Suzanne Nelsen, and Steve Leyrer
Control of Internal Stresses in Injection Molded Parts Through the Use of
Vibrational Molding, RHEOMOLDINGSM, Technology
Akihisa Kikuchi, Marc Galop, Harold L. Brown, and Alexander Bubel
Experimental Determination of Optimized Vibration-assisted Injection Molding
Processing Parameters for Atactic Polystyrene
Alan M. Tom, Akihisa Kikuchi, and John P. Coulter
Vibrated Gas Assist Molding: Its Benefits in Injection Molding
J.P. Ibar

Chapter 6: Mold Making and Plasticisation

iii

215
223

229
229

237

245
253

259

Advances in Stack Molding Technology

259
Vincent Travaglini and Henry Rozema
Advanced Valve Gate Technology for Use in Specialty Injection Molding
267
John Blundy, David Reitan, and Jack Steele
In-mold Labeling for High Speed, Thin Wall Injection Molding
273
Gary Fong
Advances in Fusible Core Technique
281
E. Schmachtenberg and O. Schrder
Processing Glass-filled Polyethylene on a Twin-screw Injection Molding
Extruder
287
David Bigio, Rajath Mudalamane, Yue Huang and Saeid Zerafati
Injection Molding by Direct Compounding
295
Bernd Klotz
Improvement of the Molded Part Quality: Optimization of the Plastification Unit 301
S. Boelinger and W. Michaeli

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Table of Contents

Non-return Valve with Distributive and Dispersive Mixing Capability

Chris Rauwendaal

307

Index

313