Improved contact lens injection molding production by 3D printed conformal cooling channels

Y. F. Lin, J. R. Wu, Bernard Haochih Liu, W. C.J. Wei, A. B. Wang, R. C. Luo

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

In this research, the combination of finite element simulation and 3D printing enabled casting was adapted to overcome the restrictions on traditional machining processes, we presented a fabrication method for complex injection molding mold pieces with a shorter time and lower processing cost than traditional machining and laser-or e-beam-based 3D printing methods. Based on the plastic injection molding simulation results, which considered the cooling rate of the contact lens mold and the cooling time of each part of the mold, we concluded that the design of conformal cooling channel locating at contact lens mold had little influence on the period of injection. When the mold cavities had smaller total volume ratio than the sprue, such as our contact lens mold, the cooling time of the sprue would be longer than the mold cavities, therefore more attention should be paid on the cooling of the sprue. However, the simulation results showed that the cooling efficiency did not increased significantly when a conformal cooling channel was placed in the sprue bush. But the cooling time reduce about 20%. In other words, the cooling of sprue bush dominated production cycle time. Therefore, a smart mold with real-time temperature monitoring was made with 3DP and mold flow simulation for this work.

Original languageEnglish
Title of host publicationSII 2017 - 2017 IEEE/SICE International Symposium on System Integration
PublisherInstitute of Electrical and Electronics Engineers Inc.
Pages89-94
Number of pages6
ISBN (Electronic)9781538622636
DOIs
Publication statusPublished - 2018 Feb 1
Event2017 IEEE/SICE International Symposium on System Integration, SII 2017 - Taipei, Taiwan
Duration: 2017 Dec 112017 Dec 14

Publication series

NameSII 2017 - 2017 IEEE/SICE International Symposium on System Integration
Volume2018-January

Other

Other2017 IEEE/SICE International Symposium on System Integration, SII 2017
CountryTaiwan
CityTaipei
Period17-12-1117-12-14

Fingerprint

contact lenses
Contact lenses
Injection Molding
injection molding
Injection molding
Lens
Cooling
Contact
cooling
Machining
machining
printing
Printing
Cavity
simulation
Plastics molding
cavities
Flow simulation
Flow Simulation
Finite Element Simulation

All Science Journal Classification (ASJC) codes

  • Modelling and Simulation
  • Instrumentation
  • Artificial Intelligence
  • Computer Science Applications
  • Engineering (miscellaneous)
  • Materials Science (miscellaneous)
  • Control and Optimization

Cite this

Lin, Y. F., Wu, J. R., Liu, B. H., Wei, W. C. J., Wang, A. B., & Luo, R. C. (2018). Improved contact lens injection molding production by 3D printed conformal cooling channels. In SII 2017 - 2017 IEEE/SICE International Symposium on System Integration (pp. 89-94). (SII 2017 - 2017 IEEE/SICE International Symposium on System Integration; Vol. 2018-January). Institute of Electrical and Electronics Engineers Inc.. https://doi.org/10.1109/SII.2017.8279194
Lin, Y. F. ; Wu, J. R. ; Liu, Bernard Haochih ; Wei, W. C.J. ; Wang, A. B. ; Luo, R. C. / Improved contact lens injection molding production by 3D printed conformal cooling channels. SII 2017 - 2017 IEEE/SICE International Symposium on System Integration. Institute of Electrical and Electronics Engineers Inc., 2018. pp. 89-94 (SII 2017 - 2017 IEEE/SICE International Symposium on System Integration).
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abstract = "In this research, the combination of finite element simulation and 3D printing enabled casting was adapted to overcome the restrictions on traditional machining processes, we presented a fabrication method for complex injection molding mold pieces with a shorter time and lower processing cost than traditional machining and laser-or e-beam-based 3D printing methods. Based on the plastic injection molding simulation results, which considered the cooling rate of the contact lens mold and the cooling time of each part of the mold, we concluded that the design of conformal cooling channel locating at contact lens mold had little influence on the period of injection. When the mold cavities had smaller total volume ratio than the sprue, such as our contact lens mold, the cooling time of the sprue would be longer than the mold cavities, therefore more attention should be paid on the cooling of the sprue. However, the simulation results showed that the cooling efficiency did not increased significantly when a conformal cooling channel was placed in the sprue bush. But the cooling time reduce about 20{\%}. In other words, the cooling of sprue bush dominated production cycle time. Therefore, a smart mold with real-time temperature monitoring was made with 3DP and mold flow simulation for this work.",
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Lin, YF, Wu, JR, Liu, BH, Wei, WCJ, Wang, AB & Luo, RC 2018, Improved contact lens injection molding production by 3D printed conformal cooling channels. in SII 2017 - 2017 IEEE/SICE International Symposium on System Integration. SII 2017 - 2017 IEEE/SICE International Symposium on System Integration, vol. 2018-January, Institute of Electrical and Electronics Engineers Inc., pp. 89-94, 2017 IEEE/SICE International Symposium on System Integration, SII 2017, Taipei, Taiwan, 17-12-11. https://doi.org/10.1109/SII.2017.8279194

Improved contact lens injection molding production by 3D printed conformal cooling channels. / Lin, Y. F.; Wu, J. R.; Liu, Bernard Haochih; Wei, W. C.J.; Wang, A. B.; Luo, R. C.

SII 2017 - 2017 IEEE/SICE International Symposium on System Integration. Institute of Electrical and Electronics Engineers Inc., 2018. p. 89-94 (SII 2017 - 2017 IEEE/SICE International Symposium on System Integration; Vol. 2018-January).

Research output: Chapter in Book/Report/Conference proceedingConference contribution

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AB - In this research, the combination of finite element simulation and 3D printing enabled casting was adapted to overcome the restrictions on traditional machining processes, we presented a fabrication method for complex injection molding mold pieces with a shorter time and lower processing cost than traditional machining and laser-or e-beam-based 3D printing methods. Based on the plastic injection molding simulation results, which considered the cooling rate of the contact lens mold and the cooling time of each part of the mold, we concluded that the design of conformal cooling channel locating at contact lens mold had little influence on the period of injection. When the mold cavities had smaller total volume ratio than the sprue, such as our contact lens mold, the cooling time of the sprue would be longer than the mold cavities, therefore more attention should be paid on the cooling of the sprue. However, the simulation results showed that the cooling efficiency did not increased significantly when a conformal cooling channel was placed in the sprue bush. But the cooling time reduce about 20%. In other words, the cooling of sprue bush dominated production cycle time. Therefore, a smart mold with real-time temperature monitoring was made with 3DP and mold flow simulation for this work.

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Lin YF, Wu JR, Liu BH, Wei WCJ, Wang AB, Luo RC. Improved contact lens injection molding production by 3D printed conformal cooling channels. In SII 2017 - 2017 IEEE/SICE International Symposium on System Integration. Institute of Electrical and Electronics Engineers Inc. 2018. p. 89-94. (SII 2017 - 2017 IEEE/SICE International Symposium on System Integration). https://doi.org/10.1109/SII.2017.8279194