Study on External Gas-Assisted Mold Temperature Control...

Research ArticleStudy on External Gas-Assisted Mold Temperature Control forImproving the Melt Flow Length of Thin Rib Products in theInjection Molding Process

Phan The Nhan1 Thanh Trung Do1 Tran Anh Son2 and Pham Son Minh 1

1HCMC University of Technology and Education Hochiminh City Vietnam2Ho Chi Minh City University of Technology Vietnam

Correspondence should be addressed to Pham Son Minh minhpshcmuteeduvn

Received 20 December 2018 Revised 1 February 2019 Accepted 28 March 2019 Published 17 April 2019

Guest Editor Jianzhang Li

Copyright copy 2019 PhanTheNhan et alThis is an open access article distributed under the Creative Commons Attribution Licensewhich permits unrestricted use distribution and reproduction in any medium provided the original work is properly cited

In the injection molding process mold temperature control is one of the most efficient methods for improving product quality Inthis research an external gas-assisted mold temperature control (Ex-GMTC) with gas temperature variation from 200∘C to 400∘Cwas applied to thin wall injection molding at melt thicknesses from 02 to 06 mmThemelt flow length was evaluated through theapplication of this system to the mold of a thin rib productThe results show that the heating process achieves high efficiency in theinitial 20 s with a maximum heating rate of 64∘Cs In this case the mold surface reached 1584∘C By applying Ex-GMTC to a 02mm flow thickness the flow length increased from 3785 to 4132 mm with polypropylene (PP) material and from 1454 to 158 mmwith acrylonitrile butadiene styrene (ABS) material With the thin rib mold and use of Ex-GMTC the mold temperature variedfrom 1120∘C to 1408∘C and the thin rib height reached 70 mm

1 Introduction

Injection molding is a popular method for manufacturingplastic products However with consumer demands forhigher product quality as well as increasingly complex prod-uct geometries it is clear that the injection molding processrequires improvement In this regard mold temperaturecontrol is an effective method for solving issues encounteredduring the melt filling step [1ndash3] In general with a highmold surface temperature component quality is improvedhowever the cooling time and cycle time will both increaseBy contrast decreasing the mold surface temperature willreduce the cooling time but limit the surface quality ofthe component [4 5] Therefore a critical requirement forcurrent studies is to increase the mold surface temperaturewhile maintaining a sufficiently short cycle time

For the molding of micro products or products withthin walls mold temperature should be set as high as theequipment allows In the common molding process using amold temperature controller the mold temperature can beraised to about 90∘C by hot water flowing inside the cooling

channel [6] However in the field of electronic productionusing materials such as polycarbonate (PC) or polymethylmethacrylate (PMMA) themold temperaturemust be higherthan 100∘C In such cases many different methods have beeninvestigated for the purpose of raising mold temperature

One common solution for cases where mold temperaturemust be higher than 100∘C is the application of steam heatingto the mold plate [7] Although such a method is efficientin terms of the molding process and improving componentquality it may damage the channel and connector whenoperating at high pressure energy use is also an issue Useof an electronic heater inserted into the mold plate has alsobeen suggested The heater heats the mold cavity to thetarget temperature before the mold plate is cooled by thecooling channel This method can heat the mold to higherthan 100∘C but the heating time is an issue [8] To improvethe heating rate during mold temperature control a thinheater has been adopted to control the temperature of cavitysurfaces during the injection molding process This methodcan support fast cooling even if it is kept active for very longperiods In experiments where the heater was set at 150∘C

HindawiAdvances in Polymer TechnologyVolume 2019 Article ID 5973403 17 pageshttpsdoiorg10115520195973403

2 Advances in Polymer Technology

for a long heating period the results showed a significanteffect on sample frozen-in orientation as identified by opticalmicroscopy and confirmed by X-ray analysis This methodcould be applied to micro injection molding with a suitablesheet heater [9] However in general the electrical methodoften requires additional design and tool costs this methodalso requires an auxiliary heating source

To reduce energy wastage surface heating methods havebeen studied Chang et al studied mold heating by infraredsystems using simulations and experiments [10]Their resultsshowed that energy wastage was reduced For a high heatingrate induction heating was investigated by Chen et al [11]with the results illustrating that a large heating rate wasachieved when using a suitable coil design In additioncertain types of induction heating have been suggested suchas proximity heating [12 13] and ring coil heating [14]However with induction heating methods there remainapplication difficulties such as identifying the required coildesign for reaching a good temperature distribution andthe potential for overheating which will damage the moldmaterial For directly heating the mold surface gas-assistedmold temperature control (GMTC) has been suggestedWiththis approach hot gas flows into the mold cavity Throughheat convection the mold surface receives energy increasingits temperature In this method the heating system includesgates inserted into the mold plate for hot gas entrance andexit [15 16] Initial results showed that the cavity surfacecould be heated to over 200∘C In addition because hot gasflows into the cavity this method can heat a complex cavityHowever the mold structure becomes more complex becauseof the combining of heating systems Another disadvantageof GMTC is the temperature distribution this is an issue thatneeds to be resolved

Therefore based on the disadvantages reported forGMTCwe applied external GMTC (Ex-GMTC) inwhich thegas temperature was varied from 200∘C to 400∘C This wasapplied to thin wall injection molding at melt thicknesses of02 to 06 mm To improve the temperature distribution theheating step was achieved using four gas gates on a melt flowlength mold In this case the four gas gates were arrangedalong the cavity surface After the molding process wascomplete the length of the molding product was measuredto observe the influence of Ex-GMTC on melt flow lengthIn addition Ex-GMTC was applied to the injection mold ofa thin rib product In this application the improvement ofrib height was observed by heating the mold surface until thesurface temperature was higher than the glass temperature ofthe material In all cases simulations were used to predict theheating rate and temperature distribution Experimentallymold temperatures were determined by infrared cameraThe experiment and simulation results are compared anddiscussed

2 Simulation and Experimental Methods

In general the application of gas-assisted mold surfaceheating in injection molding is achieved using the six stepsshown in Figure 1 [17] According to this process the moldcavity is heated to the target temperature before the hot

melt is filled into the mold cavity The greatest differencecompared with the common injection molding process isthe heating in Step 2 As with our former research onmold temperature control hot gas was used as a heatingsource to increase the cavity surface temperature of theinjection mold Compared with other studies on gas heatingfor injection mold temperature control [15ndash17] Ex-GMTCis a new technique in the field of mold temperature controland can heat the cavity surface rapidly during the injectionmolding process without a significant change in the moldstructure During the heating operation two mold platesare first moved to the open position by opening the moldSecond a hot gas drier is moved to the heating position bya robot arm then the hot gas is sprued to directly contactthe cavity surface This hot gas heats the cavity surface to thetarget temperature Third after the cavity surface is heatedto the target temperature the gas drier is moved outside themolding area and the mold completely closes in preparationfor the melt filling process

In this research the Ex-GMTCsystem consisted of amoldtemperature controller a hot gas generator system (includingan air compressor air drier with a power of 12 kW and digitalvolumetric flow controller) and a robot arm for movingthe hot gas generator system to the heating position Theassembly of the Ex-GMTC system and the injection moldingmachine is shown in Figure 2 For generating the hot air theair drier was used with dimensions of 240mm x 100mm x 60mm as shown in Figure 3 A gas channel 5 mm in width and10mm in depth was cut inside the gas drierThe environmentair will press into the air drier with the pressure of 7 Bar thenthe air will flow along the gas channel and absorb the thermalenergy from thewall of air channelThe hot air will flow out atthe four gates with the hole diameter of 10 mmThe functionof the high power hot gas generator system is to support a heatsource which provides a flow of hot air up to 400∘C with aninlet gas pressure up to 7 Bar

In this study to observe the improvement of the meltflow length when using the Ex-GMTC an injection moldwas designed andmanufactured with the structure of a cavityplate as shown in Figure 4 In this case the mold wasdesigned with two cavities One had the common structureand the other was designed with an insert as shown inFigure 5 As with our previous research [15ndash17] this type ofdesign helped to increase the heating efficiency and bettercontrol the heating area The mold and the Ex-GMTC wereassembledwith a SW-120Bmoldingmachine fromShineWellMachinery Co Ltd as shown in Figure 6

To study the temperature distribution of the heating areaa simulation model was built to represent the experimentsBecause a cavity insert (Figure 5) was used an insulationcomponent covered the heating area therefore the simu-lation model includes only two volumes the heating areavolume and the hot gas volume as shown in Figure 7In contrast with former papers on gas-assisted temperaturecontrol for injection molding processes [15ndash17] the hot gaswas sprued to the heating area via four gates to increase thetemperature uniformity of the cavity surface The simulationmodel and meshing model are shown in Figure 7 and theboundary conditions are shown in Table 1 To improve the

Advances in Polymer Technology 3

1 2 3 4 5 6

Ejection time

Heating target

temperatureM

old

tem

pera

ture

Cycle time (s)

1 Mold closes to heating position3 Mold closes to molding position5 Cooling process

2 Hot gas heats the mold surface4 Filling and packing process6 Mold opens for part ejection

Tem

pera

ture

(∘C)

Figure 1 General process of gas-assisted mold surface heating in injection molding [17]

4 5 6

1

2

3

(1) Injection molding machine(2) Core side(3) Cavity side(4) Robot arm(5) Hot-gas generator(6) The position for hang on the robot arm

Figure 2 External gas-assisted mold temperature control heating devices


Table 1 Simulation parameters for studying melt flow length

Simulation parametersAir inlet temperature of air drier 30∘C 7 barAir outlet temperature of air drier (∘C) 30 200 250 300 350 400Air density (kgm3) [18] 1165 0746 0680 0616 0570 0524Heat capacity of air (JkglowastK) [18] 1004 1026 1035 1046 1057 1068Thermal-expansion coefficient of air (x10minus3Kminus1) [18] 332 21 193 176 164 152Air pressure 1 atmInitial temperature of mold insert 30∘CAluminum density - ASTM B209-14 2702 kgm3Heat capacity of aluminum - ASTM B209-14 903 JkglowastKThermal conductivity of aluminum - ASTM B209-14 237 WmlowastKP20 steel density - ASTM A681 7870 kgm3Heat capacity of P20 steel - ASTM A681 460 JkglowastKThermal conductivity of P20 steel - ASTM A681 29 WmlowastKSimulation type TransientHeating time 0 s 997888rarr 30 s

Air outlet to environment (i) Environment pressure 1 atm(ii) Air temperature 30∘C

Initial air volume(i) Air velocity 0 ms(ii) Air pressure 1 atm(iii) Air temperature 30∘C

Hot air gates

Middle plate

Heater hole

Air inlet

Figure 3 Air drier component parts

RunnerGate entrance

Cavity insert

Cavity

Figure 4 Cavity plate of melt flow length mold

simulation accuracy the cavity insert was meshed with ahex dominant element with seven layers in the thicknessdirection In addition with the air volume a tetrahedronelement used with a smaller element size was set up at thehot gas inlet location The heating process was simulated byANSYS software with the same experimental parameters

After studying the influence of Ex-GMTC on the meltflow length of the injection molding process this heatingmethodwas applied to a real product with a thin rib as shownin Figure 8 The thin rib had a thickness varying from 05to 03 mm and a height of 70 mm This rib size is oftenused in plastic products for the electrical field In many casesa thin rib is used to increase the rigidness of the producthowever in the molding process fully filling this type of ribis a challenge of rapid cooling of the melt as it enters thecavity To improve the process of filling melt into a thin ribEx-GMTC was applied using one gate of hot gasThe heatingarea and the cavity structure are shown in Figure 9 The hotgas was sprued directly on the center of the heating areaThen the temperature distribution and temperature valuesat three points as shown in Figure 9 were collected Forobserving the temperature distribution along the thickness ofmold a 3D thermal fluid analysis was performed by ANSYSsoftware Figure 10 shows the simulation model of the thinrib mold In simulation the heat transfer mode around allexternal surfaces of mold plate was set at free convection tothe air with ambient temperature at 30∘C and a heat transfercoefficient of 10Wm2KThe same with experiment the areaat the cavity center was designed with a steel insert to improvethe heating efficiency This cavity insert had dimensions of 40times 25 times 10 mm3 A 400∘C gas inlet was used for simulation

3 Results and Discussion

31 Effect of External Gas-Assisted Mold Temperature Controlon the Heating Process of a Melt Flow Length Mold In ourformer research [15ndash17] when hot gas was used to raisecavity temperature heating efficiency was relatively goodHowever in addition to the disadvantage of the complexmold structure the temperature distribution within thecavity is an issue in need of further research Therefore in


A A

2 holes Oslash8 2 holes Oslash5 2 holes M4

A - AR4 B

12032 3 O

O005O005

B101

R2

R2

95465

4 6

19000-02

17500500

600 -001

1200 -001

1200 -001

1800 -001

0200-01

(a)

(b)

Figure 5 Mold insert for studying melt flow length (a) Design of mold insert (b) Experimental mold insert

Ex-GMTC controller

Hot gasgates

Coreplate

position

Cavityplate

position

Robot arm

Figure 6 External gas-assisted mold temperature control experiment model

this research with Ex-GMTC used for the injection moldingprocess the heating process was observed in relation to theheating rate and temperature distribution within the cavityTo study the application of Ex-GMTC themoldwas designedas in Figure 4 with the gas drier having four hot gas gatesThese gates were arranged along the cavity to improve thetemperature distribution and heating rate As an initial step

heating was simulated using the model as in Figure 7 Theheating process was performed at gas temperatures of 200∘C250∘C 300∘C 350∘C and 400∘C a heating time of 30 s andan initial cavity surface temperature of 30∘C

The simulation results show the temperature distributionof the cavity at the top view as in Figure 11 and the crosssection A-A as in Figure 12 The temperature at the four


Heating surface

Cooling channel

Gas drier

`

P1

P2

P3

P4

Cavity insert

12

10

(a) Heating position (b) Simulation model

000 10000

150005000

20000 (mm)

(c) Meshing model

Figure 7 Model of Ex-GMTC with 4 gas gates

Thin rib

Melt entrance

Rib 1

03

80

05

R520

252 7

Rib 2

Figure 8 Thin rib model

measurement points was collected as in Table 2 Accordingto the temperature distribution simulation results the cavitysurface underwent a relatively balanced heating processalthough there were some higher temperature regions nearthe hot gas gates The differences in temperature are clearerat the beginning of the heating period because the heatingrate at the gas gates was very strong during this period Thisphenomenon is clear at all gas temperatures By contrastwhen a higher gas temperature was used (Figures 11(e) and12) the difference in temperature is also clear at the endof heating period This is because of an imbalance in thethermal energy between the receiving thermal energy (nearthe gas gates) and the calorific power area (distant fromthe gas gate) This phenomenon could be observed clearerwith the temperature distribution at the cross section A-A asin Figure 12 At higher gas heating temperature the cavity

surface shows a trend of releasing greater calorific power tothe environment Therefore in the area distant from the gasgate the temperature was much lower than that of the areanear the gas gate This result could be observed clearly at a400∘C gas temperature and heating time of 30 s To reducethis imbalance the gas drier could be designed with more gasgates However as compared with other heating methods forinjection molds [3 8ndash10] the temperature distribution resultshows that this heating method with four gas gates and acavity length of 175 mm is highly advantageous In additionthe effect of cavity insert was clarified by the appearing ofhigher temperature area at the cavity surface

To assess heating rate the temperatures at four pointswere collected and compared as shown in Figure 13 Accord-ing to the results the raising of temperature showed alimitation of the heating process The heating efficiency


Table 2 Simulation results of mold cavity temperature after heating for the melt flow length mold

Heating Time (s) Position Gas temperature (∘C)200 250 300 350 400

5

P1 623 732 833 925 1028P2 581 693 814 845 954P3 566 672 798 824 913P4 578 660 789 766 884

10

P1 760 916 1091 1158 1256P2 783 926 1095 1155 1268P3 745 844 1056 1043 1157P4 744 868 1044 1051 1156

15

P1 908 1057 1190 1318 1484P2 872 1027 1175 1237 1442P3 866 1015 1163 1242 1421P4 855 1013 1154 1310 1416

20

P1 922 1140 1256 1478 1548P2 902 1109 1229 1466 1537P3 883 1081 1197 1459 1511P4 848 1053 1171 1459 1505

25

P1 956 1162 1298 1474 1601P2 921 1124 1255 1440 1586P3 912 1126 1233 1421 1578P4 866 968 1174 1438 1557

30

P1 965 1196 1329 1517 1613P2 944 1177 1280 1479 1594P3 943 1169 1274 1453 1581P4 840 1062 1196 1407 1525

was high only at the beginning of the heating step after20 s the temperature increase was slowed This result wasbecause of heat convection between the hot gas and themold surface At the same gas temperature when the cavitytemperature increased the transfer of thermal energy waslower Therefore with the four gas temperatures highlyefficient heating was achieved within the first 20 s with amaximum heating rate of 64∘Cs with the 400∘C gas Inthis case although there is a limitation in the raising oftemperature the mold surface reached 1584∘C which wassufficiently high for almost all of the melt to flow easily intothe cavity By contrast this limitation reduced overheating ofthemold insert especially withmicro injection moldingThisis also an advantage of Ex-GMTC as compared with otherheating methods for injection molds [10ndash14]

To verify the accuracy of the simulation result the exper-iment was conducted with the same boundary conditions asused in the simulation The experiment was conducted 10times for each case and the average value is presented hereinThe temperatures at four points (Figure 7(a)) were collectedusing a thermal camera and compared with the simulationresults as shown in Figure 13 Based on these comparisonsthe temperature difference between the simulations andexperimentswas lower than 12∘CThis difference is because ofa measurement delay of the thermal camera especially as thethermal energy can transfer quickly from the high tempera-ture area to the lower temperature area However in general

this result demonstrates that the simulations and experimentsshowed good agreement In addition the limitation in theheating process was observed experimentally

32 Effect of External Gas-Assisted Mold Temperature Controlon Melt Flow Length In injection molding cavity surfacetemperature has a strong influence on melt flow lengthbecause of a reduction of the freeze layer [1 5] This propertyis a key aspect of the molding process especially withmicro products or thin-walled components In this studyto increase the cavity temperature Ex-GMTC was appliedto the melt flow length mold as in Figure 4 To observethe effect of Ex-GMTC on the melt flow length the heatingstep was achieved at a gas temperature of 400∘C and theheating time was varied from 5 to 20 s After the heatingstep the gas drier was moved outside the molding area andthe two-half mold plate was closed for the filling step tocommence (Step 3 in Figure 1) In this period the moldtemperature will change and the mold temperature at theend of this period impacts the melt flow length In thereal molding cycle it takes about 6 s from the end of theheating period to the start of the filling step Thereforeafter the heating period was finished the mold temper-ature was measured for comparison with the melt fillingresult For the molding experiment polypropylene (PP 1100Nfrom Advanced Petrochemical Company) and acrylonitrilebutadiene styrene (ABS 750SW from Kumho Petrochemical


Table 3 Molding parameters for the melt flow length experiment

No Molding parameters ValuePP material ABS material

1 Melt temperature 210∘C 230∘C2 Injection pressure 60 kgcm2

3 Cooling time 20 s4 Injection speed 50 mms5 Injection time 05 s6 Packing time 25 s7 Heating time 5 s 10 s 15 s 20 s8 Initial mold temperature 30∘C9 Glass transition temperature 100∘C 105∘C

Cooling channels

Heating area

Cavity area

Rib location Rib locationMeasuring points

1 2 3

Figure 9 Mold plate of thin rib with the cavity insert

Company) were used with the material properties as inTable 3

Using the infrared camera we determined the temper-ature distribution of the melt flow length mold (Figure 14)This shows that with heating times of 5 10 15 and 20 s at thebeginning of melt filling step the temperature of the cavitysurface is maintained at 628∘C 949∘C 1212∘C and 1337∘Crespectively In addition the uniformity of the temperaturedistribution was clearly improved after the heating stepThis result could be explained by the heat conduction ofthe mold insert In this period the thermal energy wouldhave transferred from the higher temperature region tothe lower temperature region Therefore the temperature

Cavity insert

Insert cover

Insert block

Cooling channel

Heating surface

Micro rib

Hot gas inlet Gas outlet

B

B

Figure 10 Simulation model of thin rib heating step

distribution of themold insert would bemore uniform In theexperiment the temperature difference was less than 5∘C forall cavity areas (175mm times 12 mm)This degree of temperatureuniformity ismuch improved over that of our former research[15ndash17] and could help reduce thewarpage of plastic productsThe result also indicates that with a proper layout of the gasgates Ex-GMTC could be applied to the complex geometryof the mold cavity

Experimentally the molding process was operated withdifferent heating times The plastic components were evalu-ated as shown in Figures 15 and 16 With the plastic materialand molding parameters shown in Table 3 the experimentwas performed with melt flow thicknesses of 02 04 and 06mmThe results show that the melt flow length was improved


10s

40 72 105 138 170

15s

20s

25s

30s

5s

Temperature [∘C]

(a) Gas temperature 200∘C

10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]

(b) Gas temperature 250∘C

10s

15s

20s

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30s

5s40 72 105 138 170

Temperature [∘C]

(c) Gas temperature 300∘C

10s

15s

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5s40 72 105 138 170

Temperature [∘C]

(d) Gas temperature 350∘C

10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]

(e) Gas temperature 400∘C

Figure 11 Temperature distribution at the cavity surface of the melt flow length mold after 30 s heating at different gas temperatures

30 s

25 s

20 s

15 s

10 s

5 s

(lowast) Hot air gate (lowast) Melt entrance

40 72 105 138 170

Temperature [∘C]

Figure 12 Temperature distribution at the cross section A-A withthe gas heating of 400∘C

with the application of Ex-GMTCand a heating time between5 and 20 s The improvement is clearer with heating timesof 15 and 20 s because the cavity surface temperature washeated to over 110∘C in these cases which is higher than theglass transition temperature of both the PP andABSmaterials(Table 4) The percentage improvement in flow length wascalculated and is shown in Figure 17 The results show thatby applying Ex-GMTC for a 06 mm flow thickness the meltflow length could be improved by 235with the PPmaterialand 223 with the ABS material With the 02 mm flowthickness the flow length increased from 3785 to 4132 mmwith the PPmaterial and from 1454 to 158 mmwith the ABSmaterial

33 Improving the in Rib Filling Step by External Gas-Assisted Mold Temperature Control To assess the efficiencyof Ex-GMTC on the injection molding cycle the mold for athin rib product was usedThe dimensions of this product areshown in Figure 8 with rib thickness varied from 03 to 05mm and a rib height of 70 mm The melt material was ABSFor the common injection molding process mold tempera-ture should be set in the range 20∘C to 80∘C However with athinwall product themold temperaturemust be set as high aspossible to allow for complete filling of the cavityThis readilyallows flow because of the reduction of the freeze layer of themelt flow [5] However when the mold temperature is highenergywastagewill also be high in addition other issues suchaswarpage and flashing can become evident Tomitigate such


0 5 10 15 20 25 30

Heating time (s)

(lowast) Ex Experiment Si Simulation

180

160

140

120

100

80

60

40

20

P1_200∘C_ExP1_200∘C_SiP1_250∘C_ExP1_250∘C_SiP1_300∘C_Ex

P1_300∘C_SiP1_350∘C_ExP1_350∘C_SiP1_400∘C_ExP1_400∘C_Si

Tem

pera

ture

(∘C)

(a) Temperature at point P1



0 5 10 15 20 25 30

Heating time (s)

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pera

ture

(∘C)


(b) Temperature at point P2



0 5 10 15 20 25 30

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(∘C)


(c) Temperature at point P3



0 5 10 15 20 25 30

Heating time (s)

180

160

140

120

100

80

60

40

20

Tem

pera

ture

(∘C)


(d) Temperature at point P4

Figure 13 Temperature history at four points with different gas sources

issues local mold temperature control was presented in thisstudy with the Ex-GMTC method Rather than maintainingall mold plates at a high temperature Ex-GMTC is applied tothe cavity area by local gas preheating at the beginning of themolding cycle The high temperature at the cavity center willreduce the pressure drop of the melt flow as it enters the moldcavity [2 4] Figure 9 shows the cavity plate which includesthe cavity area and the melt entrance area

With the above structure the area at the cavity centerwas redesigned with a steel insert to improve the heatingefficiencyThis insert had dimensions of 40 times 25times 10 mm3 Agas drier with one gate and a gas temperature of 400∘C were

used for these experiments To observe the influence of Ex-GMTCon the filling step of the thin rib the commonmoldingcycle was initially operated with molding temperatures from45∘C to 75∘C In these cases the mold temperature controllerwas used with water flow inside the cooling channel ThenEx-GMTCwas appliedwith heating times from4 to 10 s Afterthe heating step the melt was filled into the cavity after 6 s forthe mold closing All thin rib experiments used the same ABSmaterial shown in Table 3

To study the heating step for the thin rib mold thetemperature of the cavity surface was measured at threepoints as shown in Figure 9 By experiment the temperature


654

688

701

662

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631

651

Simulation Experiment

170

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1700

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Unit ∘C(a) Heating time 5 s

956

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962

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954


170

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Unit ∘C(b) Heating time 10 s

1258

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1185

1198

1201

1265


170

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40

1700

162

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45400∘C

Unit ∘C(c) Heating time 15 s

1354

1358

1367

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1289

1305

1308

1337


170

138

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40

1700

162

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45400∘C

Unit ∘C(d) Heating time 20 s

Figure 14 Temperature distribution of the melt flow mold at the beginning of melt filling step

Heating time20 s

Heating time15 s

Heating time10 s

Heating time 5 s

Without heating

02 mm thickness

3785 mm

04 mm thickness

7468 mm 11641 mm

3836 mm 7777 mm 12097 mm

3896 mm 7854 mm 12335 mm

4024 mm 8185 mm 13290 mm

4132 mm 9086 mm 14326 mm06 mm thickness

Figure 15 Experimental results for melt flow length with the polypropylene material at different heating times

histories are given in Table 4 and Figure 18 The temperaturehistories in Figure 18 show that at the end of the heating stepthe mold temperature reached 1120 1213 1325 and 1408∘Cat heating times of 4 6 8 and 10 s respectively In additionafter 6 s for mold closure the temperature of the heatingsurface decreased by about 10∘C with the thin rib mold Toverify the temperature uniformity the thermal camera was

used to determine the temperature distribution in the thin ribmold at the end of the heating stepThese results are shown inFigure 20 The results show that the temperature uniformitywas very good and the heating process influences only theheating area For observing the temperature distribution anduniformity along the thickness of mold the heating step wassimulated with the gas heating of 400∘C and the simulation


Heating time20 s

Heating time15 s

Heating time10 s

Heating time5 s

Without heating

02 mm thickness

1454 mm

04 mm thickness

2556 mm

1469 mm 2647 mm

1485 mm 2686 mm

1526 mm 2789 mm

1580 mm 3024 mm

3604 mm

3741 mm

3809 mm

4011 mm

4369 mm06 mm thickness

Figure 16 Experimental results for melt flow length with the acrylonitrile butadiene styrene material at different heating times

Heating time

Without heating

5 s 10 s 15 s 20 s

02 mm04 mm06 mm

im

prov

emen

t

25

20

15

0

5

10

(a) PP material

im

prov

emen

t

Without heating

5 s 10 s 15 s 20 s

Heating time

25

20

15

0

5

10

02 mm04 mm06 mm

(b) ABS material

Figure 17 Improvement of melt flow length with the polypropylene and acrylonitrile butadiene styrene materials at different heating time

model as in Figure 10 The temperature distribution at thecross section B-B was shown in Figure 19 According tothis result the highest temperature was located at the centersurface of cavity insertThemold surface of the rib is not closeto the gas heating gate so the heating effect is not as clearas the cavity insert Both simulation and experimental resultsshow that the temperature difference between the three pointswas less than 10∘CThe temperature difference between Point

1 and Point 3 was lower than 32∘C The more consistent thetemperature between Points 1 and 3 the more balanced themelt filling into the two ribs In addition the temperature atthe center heating area (Point 2) was always higher than thatat the other points This is because of the closer proximity ofthe gas gate to Point 2 than to the other points

At each mold temperature the molding cycle was per-formed 20 times to reach system stability before the next


(lowast) Heating time 4 s

Time (s)

End of heating step

Time for mold closing

Point 1Point 2Point 3

Melt fills into the cavity

Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(a)


End of heating step



Time (s)


Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(b)


End of heating step



Time (s)


Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(c)


Time (s)

End of heating step




Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(d)

Figure 18 Temperature histories of the thin rib mold surface at three points

10 cycles were used for comparing rib height After themolding step the molding samples were collected and ribheights measured The results are shown in Figures 21 and22 According to these results when the mold temperatureincreased from 45∘C to 75∘C the rib height increased from28 to 42 mm When Ex-GMTC was used with 400∘C gasalthough the highest temperature was focussed on the cavityinsert (Figure 19) the improvement of thin rib was observedclearly In detail when the mold temperature varied from1120∘C to 1408∘C the thin rib height reached a maximumof 70 mm This development is due to the reduction of thefrozen layer when the melt flows through the cavity insertwhich helps to increase the filling pressure at the thin ribarea Figure 22 also shows that the height of two ribs was

different when using the mold temperature controller withhot water flow inside the cooling channel This is becauseof the nonsymmetry of the mold structure the temperaturedistribution inside the mold was impacted especially inthe lower mold temperature case On the contrary withEx-GMTC the heating only affected the molding surfacetherefore the mold structure had almost no influence on theheating result As such the height of two thin ribs was moreuniform than with the hot water control method

4 Conclusions

In this research external gas-assisted mold temperaturecontrol (Ex-GMTC) was applied to the injection molding


Heating time 10 s

Heating time 8 s

Heating time 6 s

Heating time 4 s

1208 1237 1189

1256 1275 1238

1345 1367 1329

1441 1478 1432

20 55 90 125 160

[∘C]Temperature

Figure 19 Temperature distribution at the cross section B-B with the thin rib model

cycle to improve mold filling ability The simulations andexperiments were performed with molds of melt flow lengthand thin rib For the mold of melt flow length the gastemperaturewas varied from200∘C to 400∘Cand themoldingcycle was operated at component thicknesses of 02 04 and06 mm With the thin rib mold Ex-GMTC was performedusing 400∘C gas at the center of the cavity The filling ofmelt into the thin rib was observed when using (i) a moldtemperature controller with hot water flowing inside thecooling channel and (ii) Ex-GMTC Based on the results thefollowing conclusions were obtained

(i) With a length of 175mm the cavity surface of themeltflow lengthmold showed a relatively balanced heatingprocess when using four hot gas gates although therewere some higher temperature regions near the gatesHeating efficiency was high at the beginning of theheating step however after 20 s the temperatureincrease slowed This result was because of heat

convection between the hot gas and the mold surfaceThehighest heating rate achievedwas 64∘Cswith the400∘C gas

(ii) Because of heat convection the simulations andexperiments showed that Ex-GMTC has a limitationin terms of heating efficiency Nevertheless with themelt flow length mold the mold surface reached1584∘C at which temperature almost all of the meltcould flow easily into the cavity

(iii) By applying Ex-GMTC for the 06mmflow thicknessthe melt flow length could be improved by 235withthe PP material and 223 with the ABS materialWith the 02-mm flow thickness the flow length alsoincreased from3785 to 4132mmwith the PPmaterialand from 1454 to 158 mm with the ABS material

(iv) With the thin rib mold when the mold temperatureincreased from 45∘C to 75∘C the rib height wasincreased from 28 to 42 mm When the Ex-GMTC


1600153

144

135

126

117

108

99

90

81

72

63

54

45

36

27200∘C

(a) Heating time 4 s Max Temperature 1120∘C

1600153

144

135

126

117

108

99

90

81

72

63

5445

36

27200∘C

(b) Heating time 6 s Max Temperature 1213∘C

1600153

144

135

126

117

108

99

90

81

72

63

54

45

36

27200∘C

(c) Heating time 8 s Max Temperature 1325∘C

1600153

144

135

126

117

108

99

90

81

72

63

5445

36

27200∘C

(d) Heating time 10 s Max Temperature 1408∘C

Figure 20 Temperature distribution at the end of the heating step for the thin rib cavity at different heating times

450

550

650

750

28 mm

32 mm

38 mm

42 mm ∘C

∘C

∘C

∘C

(a) Mold temperature controlwith the hot water

1408

1325

1213

1120

70 mm

64 mm

62 mm

52 mm ∘C

∘C

∘C

∘C

(b) Mold temperature controlwith Ex-GMTC

Figure 21 Measurement of thin rib height at different cavity temperatures


Table 4 Experimental results for cavity temperature with the thin rib mold at different heating times

Measuring point Measuring time (s) Heating time (s)4 6 8 10

1

0 30 30 30 302 992 1002 1012 10224 1186 1199 1201 12116 1164 1234 1242 12568 1111 1215 1326 133510 1070 1180 1295 142312 1155 1267 140814 1220 137216 1330

2

0 30 30 30 302 1012 1021 1033 10424 1206 1219 1222 12366 1185 1255 1266 12728 1167 1244 1347 135110 1121 1219 1324 145812 1184 1302 144214 1251 141616 1381

3

0 30 30 30 302 992 1003 1012 10234 1162 1175 1183 11996 1141 1224 1234 12488 1104 1201 1305 131110 1056 1172 1289 141412 1132 1257 138314 1211 134516 1311

Heating time Mold closing time

Rib

heig

ht (m

m)

ABS material

Rib 1Rib 2

75

70

65

60

55

50

45

40

35

30

25

2035 45 55 65 75 110 120 130 140 150

Mold temperature (∘C)

Figure 22 Improvement of thin rib height at different cavitytemperatures

was used the mold temperature varied from 1120∘Cto 1408∘C and the thin rib height reached 70 mmBecause the Ex-GMTC was not influenced by mold

structure the heating method supported a bettertemperature distribution than that of the hot watercontroller method as a result a better balance in meltflow could be achieved

Data Availability

The data used to support the findings of this studyare available from the corresponding author uponrequest

Conflicts of Interest

The authors declare that they have no conflicts of interest

Authorsrsquo Contributions

Phan The Nhan and Pham Son Minh conceived ofthe presented idea and developed the simulation andexperimental methods Phan The Nhan and ThanhTrung Do verified the simulation results All authorsdiscussed the results and contributed to the finalmanuscript


Acknowledgments

This researchwas supported by theMinistry of Education andTraining Vietnam the Ministry of Science and TechnologyVietnam and HCMC University of Technology and Edu-cation Hochiminh City Vietnam The authors are gratefulto Mr Nguyen Ho Mr Bui Huu Manh Mr Nguyen ThanhNhan Mr Dang Ngoc Son and Mr Tran Van Tron for theirhelp in conducting the study experiments

References

[1] L Zema G Loreti A Melocchi A Maroni and A GazzanigaldquoInjectionmolding and its application to drug deliveryrdquo Journalof Controlled Release vol 159 no 3 pp 324ndash331 2012

[2] M Vazquez and B Paull ldquoReview on recent and advancedapplications of monoliths and related porous polymer gels inmicro-fluidic devicesrdquo Analytica Chimica Acta vol 668 no 2pp 100ndash113 2010

[3] M-S Huang and Y-L Huang ldquoEffect of multi-layered induc-tion coils on efficiency and uniformity of surface heatingrdquoInternational Journal of Heat and Mass Transfer vol 53 no 11-12 pp 2414ndash2423 2010

[4] S-C Nian C-Y Wu and M-S Huang ldquoWarpage control ofthin-walled injection molding using local mold temperaturesrdquoInternational Communications in Heat and Mass Transfer vol61 no 1 pp 102ndash110 2015

[5] S Meister and D Drummer ldquoAffecting the ageing behaviourof injection-moulded microparts using variothermal mouldtemperingrdquo Advances in Mechanical Engineering vol 2013Article ID 407964 7 pages 2013

[6] F BaruffiM Calaon andG Tosello ldquoEffects of micro-injectionmoulding process parameters on accuracy and precision ofthermoplastic elastomer micro ringsrdquo Precision Engineeringvol 51 pp 353ndash361 2018

[7] M-C Jeng S-C Chen P S Minh J-A Chang and C-SChung ldquoRapid mold temperature control in injection moldingby using steam heatingrdquo International Communications in Heatand Mass Transfer vol 37 no 9 pp 1295ndash1304 2010

[8] W Guilong Z Guoqun L Huiping and G Yanjin ldquoAnalysisof thermal cycling efficiency and optimal design of heat-ingcooling systems for rapid heat cycle injection moldingprocessrdquoMaterials amp Design vol 31 no 7 pp 3426ndash3441 2010

[9] S Liparoti A Sorrentino and G Titomanlio ldquoFast cavitysurface temperature evolution in injection molding control ofcooling stage and final morphology analysisrdquo RSC Advancesvol 6 pp 99274ndash99281 2016

[10] P-C Chang and S-J Hwang ldquoSimulation of infrared rapidsurface heating for injection moldingrdquo International Journal ofHeat andMass Transfer vol 49 no 21-22 pp 3846ndash3854 2006

[11] S-C Chen W-R Jong Y-J Chang J-A Chang and J-C Cin ldquoRapid mold temperature variation for assisting themicro injection of high aspect ratio micro-feature parts usinginduction heating technologyrdquo Journal of Micromechanics andMicroengineering vol 16 no 9 pp 1783ndash1791 2006

[12] D Yao T E Kimerling and B Kim ldquoHigh-frequencyproximityheating for injection molding applicationsrdquo Polymer Engineer-ing amp Science vol 46 no 7 pp 938ndash945 2006

[13] S-C Chen P S Minh J-A Chang S-W Huang and C-HHuang ldquoMold temperature control using high-frequency prox-imity effect induced heatingrdquo International Communications inHeat and Mass Transfer vol 39 no 2 pp 216ndash223 2012

[14] H-L Lin S-C Chen M-C Jeng P S Minh J-A Changand J-R Hwang ldquoInduction heating with the ring effect forinjection molding platesrdquo International Communications inHeat and Mass Transfer vol 39 no 4 pp 514ndash522 2012

[15] S-C Chen R-D Chien S-H Lin M-C Lin and J-AChang ldquoFeasibility evaluation of gas-assisted heating for moldsurface temperature control during injection molding processrdquoInternational Communications in Heat and Mass Transfer vol36 no 8 pp 806ndash812 2009

[16] S-C Chen C-Y Lin J-A Chang and P S Minh ldquoGas-assisted heating technology for high aspect ratiomicrostructureinjection moldingrdquo Advances in Mechanical Engineering vol2013 Article ID 282906 10 pages 2013

[17] S-C Chen P S Minh and J-A Chang ldquoGas-assisted moldtemperature control for improving the quality of injectionmolded parts with fiber additivesrdquo International Communica-tions in Heat andMass Transfer vol 38 no 3 pp 304ndash312 2011

[18] H D Baehr and K Stephan Heat and Mass Transfer SpringerNew York 2nd edition 2006

CorrosionInternational Journal of

Hindawiwwwhindawicom Volume 2018

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Analytical ChemistryInternational Journal of


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BioMed Research InternationalMaterials

Journal of


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nom

ate

ria

ls


Journal ofNanomaterials

Submit your manuscripts atwwwhindawicom


for a long heating period the results showed a significanteffect on sample frozen-in orientation as identified by opticalmicroscopy and confirmed by X-ray analysis This methodcould be applied to micro injection molding with a suitablesheet heater [9] However in general the electrical methodoften requires additional design and tool costs this methodalso requires an auxiliary heating source

To reduce energy wastage surface heating methods havebeen studied Chang et al studied mold heating by infraredsystems using simulations and experiments [10]Their resultsshowed that energy wastage was reduced For a high heatingrate induction heating was investigated by Chen et al [11]with the results illustrating that a large heating rate wasachieved when using a suitable coil design In additioncertain types of induction heating have been suggested suchas proximity heating [12 13] and ring coil heating [14]However with induction heating methods there remainapplication difficulties such as identifying the required coildesign for reaching a good temperature distribution andthe potential for overheating which will damage the moldmaterial For directly heating the mold surface gas-assistedmold temperature control (GMTC) has been suggestedWiththis approach hot gas flows into the mold cavity Throughheat convection the mold surface receives energy increasingits temperature In this method the heating system includesgates inserted into the mold plate for hot gas entrance andexit [15 16] Initial results showed that the cavity surfacecould be heated to over 200∘C In addition because hot gasflows into the cavity this method can heat a complex cavityHowever the mold structure becomes more complex becauseof the combining of heating systems Another disadvantageof GMTC is the temperature distribution this is an issue thatneeds to be resolved

Therefore based on the disadvantages reported forGMTCwe applied external GMTC (Ex-GMTC) inwhich thegas temperature was varied from 200∘C to 400∘C This wasapplied to thin wall injection molding at melt thicknesses of02 to 06 mm To improve the temperature distribution theheating step was achieved using four gas gates on a melt flowlength mold In this case the four gas gates were arrangedalong the cavity surface After the molding process wascomplete the length of the molding product was measuredto observe the influence of Ex-GMTC on melt flow lengthIn addition Ex-GMTC was applied to the injection mold ofa thin rib product In this application the improvement ofrib height was observed by heating the mold surface until thesurface temperature was higher than the glass temperature ofthe material In all cases simulations were used to predict theheating rate and temperature distribution Experimentallymold temperatures were determined by infrared cameraThe experiment and simulation results are compared anddiscussed

2 Simulation and Experimental Methods

In general the application of gas-assisted mold surfaceheating in injection molding is achieved using the six stepsshown in Figure 1 [17] According to this process the moldcavity is heated to the target temperature before the hot

melt is filled into the mold cavity The greatest differencecompared with the common injection molding process isthe heating in Step 2 As with our former research onmold temperature control hot gas was used as a heatingsource to increase the cavity surface temperature of theinjection mold Compared with other studies on gas heatingfor injection mold temperature control [15ndash17] Ex-GMTCis a new technique in the field of mold temperature controland can heat the cavity surface rapidly during the injectionmolding process without a significant change in the moldstructure During the heating operation two mold platesare first moved to the open position by opening the moldSecond a hot gas drier is moved to the heating position bya robot arm then the hot gas is sprued to directly contactthe cavity surface This hot gas heats the cavity surface to thetarget temperature Third after the cavity surface is heatedto the target temperature the gas drier is moved outside themolding area and the mold completely closes in preparationfor the melt filling process

In this research the Ex-GMTCsystem consisted of amoldtemperature controller a hot gas generator system (includingan air compressor air drier with a power of 12 kW and digitalvolumetric flow controller) and a robot arm for movingthe hot gas generator system to the heating position Theassembly of the Ex-GMTC system and the injection moldingmachine is shown in Figure 2 For generating the hot air theair drier was used with dimensions of 240mm x 100mm x 60mm as shown in Figure 3 A gas channel 5 mm in width and10mm in depth was cut inside the gas drierThe environmentair will press into the air drier with the pressure of 7 Bar thenthe air will flow along the gas channel and absorb the thermalenergy from thewall of air channelThe hot air will flow out atthe four gates with the hole diameter of 10 mmThe functionof the high power hot gas generator system is to support a heatsource which provides a flow of hot air up to 400∘C with aninlet gas pressure up to 7 Bar

In this study to observe the improvement of the meltflow length when using the Ex-GMTC an injection moldwas designed andmanufactured with the structure of a cavityplate as shown in Figure 4 In this case the mold wasdesigned with two cavities One had the common structureand the other was designed with an insert as shown inFigure 5 As with our previous research [15ndash17] this type ofdesign helped to increase the heating efficiency and bettercontrol the heating area The mold and the Ex-GMTC wereassembledwith a SW-120Bmoldingmachine fromShineWellMachinery Co Ltd as shown in Figure 6

To study the temperature distribution of the heating areaa simulation model was built to represent the experimentsBecause a cavity insert (Figure 5) was used an insulationcomponent covered the heating area therefore the simu-lation model includes only two volumes the heating areavolume and the hot gas volume as shown in Figure 7In contrast with former papers on gas-assisted temperaturecontrol for injection molding processes [15ndash17] the hot gaswas sprued to the heating area via four gates to increase thetemperature uniformity of the cavity surface The simulationmodel and meshing model are shown in Figure 7 and theboundary conditions are shown in Table 1 To improve the


1 2 3 4 5 6

Ejection time

Heating target

temperatureM

old

tem

pera

ture

Cycle time (s)



Tem

pera

ture

(∘C)


4 5 6

1

2

3








Hot air gates

Middle plate

Heater hole

Air inlet


RunnerGate entrance

Cavity insert

Cavity







A A


A - AR4 B

12032 3 O

O005O005

B101

R2

R2

95465

4 6

19000-02

17500500

600 -001

1200 -001

1200 -001

1800 -001

0200-01

(a)

(b)


Ex-GMTC controller

Hot gasgates

Coreplate

position

Cavityplate

position

Robot arm






Heating surface

Cooling channel

Gas drier

`

P1

P2

P3

P4

Cavity insert

12

10


000 10000

150005000

20000 (mm)

(c) Meshing model


Thin rib

Melt entrance

Rib 1

03

80

05

R520

252 7

Rib 2








5

P1 623 732 833 925 1028P2 581 693 814 845 954P3 566 672 798 824 913P4 578 660 789 766 884

10

P1 760 916 1091 1158 1256P2 783 926 1095 1155 1268P3 745 844 1056 1043 1157P4 744 868 1044 1051 1156

15

P1 908 1057 1190 1318 1484P2 872 1027 1175 1237 1442P3 866 1015 1163 1242 1421P4 855 1013 1154 1310 1416

20

P1 922 1140 1256 1478 1548P2 902 1109 1229 1466 1537P3 883 1081 1197 1459 1511P4 848 1053 1171 1459 1505

25

P1 956 1162 1298 1474 1601P2 921 1124 1255 1440 1586P3 912 1126 1233 1421 1578P4 866 968 1174 1438 1557

30

P1 965 1196 1329 1517 1613P2 944 1177 1280 1479 1594P3 943 1169 1274 1453 1581P4 840 1062 1196 1407 1525










Cooling channels

Heating area

Cavity area


1 2 3




Cavity insert

Insert cover

Insert block

Cooling channel

Heating surface

Micro rib


B

B





10s

40 72 105 138 170

15s

20s

25s

30s

5s

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]



30 s

25 s

20 s

15 s

10 s

5 s


40 72 105 138 170

Temperature [∘C]





0 5 10 15 20 25 30

Heating time (s)


180

160

140

120

100

80

60

40

20



Tem

pera

ture

(∘C)




0 5 10 15 20 25 30

Heating time (s)

180

160

140

120

100

80

60

40

20

Tem

pera

ture

(∘C)





0 5 10 15 20 25 30

Heating time (s)

180

160

140

120

100

80

60

40

20

Tem

pera

ture

(∘C)





0 5 10 15 20 25 30

Heating time (s)

180

160

140

120

100

80

60

40

20

Tem

pera

ture

(∘C)









654

688

701

662

604

625

631

651


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C


956

995

1001

962

926

957

960

954


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C


1258

1285

1304

1270

1185

1198

1201

1265


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C


1354

1358

1367

1380

1289

1305

1308

1337


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C



Heating time20 s

Heating time15 s

Heating time10 s

Heating time 5 s

Without heating

02 mm thickness

3785 mm

04 mm thickness

7468 mm 11641 mm

3836 mm 7777 mm 12097 mm

3896 mm 7854 mm 12335 mm

4024 mm 8185 mm 13290 mm






Heating time20 s

Heating time15 s

Heating time10 s

Heating time5 s

Without heating

02 mm thickness

1454 mm

04 mm thickness

2556 mm

1469 mm 2647 mm

1485 mm 2686 mm

1526 mm 2789 mm

1580 mm 3024 mm

3604 mm

3741 mm

3809 mm

4011 mm



Heating time

Without heating

5 s 10 s 15 s 20 s

02 mm04 mm06 mm

im

prov

emen

t

25

20

15

0

5

10

(a) PP material

im

prov

emen

t

Without heating

5 s 10 s 15 s 20 s

Heating time

25

20

15

0

5

10

02 mm04 mm06 mm

(b) ABS material







Time (s)

End of heating step




Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(a)


End of heating step



Time (s)


Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(b)


End of heating step



Time (s)


Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(c)


Time (s)

End of heating step




Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(d)




4 Conclusions



Heating time 10 s

Heating time 8 s

Heating time 6 s

Heating time 4 s

1208 1237 1189

1256 1275 1238

1345 1367 1329

1441 1478 1432

20 55 90 125 160

[∘C]Temperature









1600153

144

135

126

117

108

99

90

81

72

63

54

45

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

5445

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

54

45

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

5445

36

27200∘C



450

550

650

750

28 mm

32 mm

38 mm

42 mm ∘C

∘C

∘C

∘C


1408

1325

1213

1120

70 mm

64 mm

62 mm

52 mm ∘C

∘C

∘C

∘C






1

0 30 30 30 302 992 1002 1012 10224 1186 1199 1201 12116 1164 1234 1242 12568 1111 1215 1326 133510 1070 1180 1295 142312 1155 1267 140814 1220 137216 1330

2

0 30 30 30 302 1012 1021 1033 10424 1206 1219 1222 12366 1185 1255 1266 12728 1167 1244 1347 135110 1121 1219 1324 145812 1184 1302 144214 1251 141616 1381

3

0 30 30 30 302 992 1003 1012 10234 1162 1175 1183 11996 1141 1224 1234 12488 1104 1201 1305 131110 1056 1172 1289 141412 1132 1257 138314 1211 134516 1311


Rib

heig

ht (m

m)

ABS material

Rib 1Rib 2

75

70

65

60

55

50

45

40

35

30

25

2035 45 55 65 75 110 120 130 140 150





Data Availability







Acknowledgments


References





















Advances in



Journal of

Chemistry















Journal of





Volume 2018









Journal of


Na

nom

ate

ria

ls





1 2 3 4 5 6

Ejection time

Heating target

temperatureM

old

tem

pera

ture

Cycle time (s)



Tem

pera

ture

(∘C)


4 5 6

1

2

3








Hot air gates

Middle plate

Heater hole

Air inlet


RunnerGate entrance

Cavity insert

Cavity







A A


A - AR4 B

12032 3 O

O005O005

B101

R2

R2

95465

4 6

19000-02

17500500

600 -001

1200 -001

1200 -001

1800 -001

0200-01

(a)

(b)


Ex-GMTC controller

Hot gasgates

Coreplate

position

Cavityplate

position

Robot arm






Heating surface

Cooling channel

Gas drier

`

P1

P2

P3

P4

Cavity insert

12

10


000 10000

150005000

20000 (mm)

(c) Meshing model


Thin rib

Melt entrance

Rib 1

03

80

05

R520

252 7

Rib 2








5

P1 623 732 833 925 1028P2 581 693 814 845 954P3 566 672 798 824 913P4 578 660 789 766 884

10

P1 760 916 1091 1158 1256P2 783 926 1095 1155 1268P3 745 844 1056 1043 1157P4 744 868 1044 1051 1156

15

P1 908 1057 1190 1318 1484P2 872 1027 1175 1237 1442P3 866 1015 1163 1242 1421P4 855 1013 1154 1310 1416

20

P1 922 1140 1256 1478 1548P2 902 1109 1229 1466 1537P3 883 1081 1197 1459 1511P4 848 1053 1171 1459 1505

25

P1 956 1162 1298 1474 1601P2 921 1124 1255 1440 1586P3 912 1126 1233 1421 1578P4 866 968 1174 1438 1557

30

P1 965 1196 1329 1517 1613P2 944 1177 1280 1479 1594P3 943 1169 1274 1453 1581P4 840 1062 1196 1407 1525










Cooling channels

Heating area

Cavity area


1 2 3




Cavity insert

Insert cover

Insert block

Cooling channel

Heating surface

Micro rib


B

B





10s

40 72 105 138 170

15s

20s

25s

30s

5s

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]



30 s

25 s

20 s

15 s

10 s

5 s


40 72 105 138 170

Temperature [∘C]





0 5 10 15 20 25 30

Heating time (s)


180

160

140

120

100

80

60

40

20



Tem

pera

ture

(∘C)




0 5 10 15 20 25 30

Heating time (s)

180

160

140

120

100

80

60

40

20

Tem

pera

ture

(∘C)





0 5 10 15 20 25 30

Heating time (s)

180

160

140

120

100

80

60

40

20

Tem

pera

ture

(∘C)





0 5 10 15 20 25 30

Heating time (s)

180

160

140

120

100

80

60

40

20

Tem

pera

ture

(∘C)









654

688

701

662

604

625

631

651


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C


956

995

1001

962

926

957

960

954


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C


1258

1285

1304

1270

1185

1198

1201

1265


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C


1354

1358

1367

1380

1289

1305

1308

1337


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C



Heating time20 s

Heating time15 s

Heating time10 s

Heating time 5 s

Without heating

02 mm thickness

3785 mm

04 mm thickness

7468 mm 11641 mm

3836 mm 7777 mm 12097 mm

3896 mm 7854 mm 12335 mm

4024 mm 8185 mm 13290 mm






Heating time20 s

Heating time15 s

Heating time10 s

Heating time5 s

Without heating

02 mm thickness

1454 mm

04 mm thickness

2556 mm

1469 mm 2647 mm

1485 mm 2686 mm

1526 mm 2789 mm

1580 mm 3024 mm

3604 mm

3741 mm

3809 mm

4011 mm



Heating time

Without heating

5 s 10 s 15 s 20 s

02 mm04 mm06 mm

im

prov

emen

t

25

20

15

0

5

10

(a) PP material

im

prov

emen

t

Without heating

5 s 10 s 15 s 20 s

Heating time

25

20

15

0

5

10

02 mm04 mm06 mm

(b) ABS material







Time (s)

End of heating step




Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(a)


End of heating step



Time (s)


Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(b)


End of heating step



Time (s)


Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(c)


Time (s)

End of heating step




Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(d)




4 Conclusions



Heating time 10 s

Heating time 8 s

Heating time 6 s

Heating time 4 s

1208 1237 1189

1256 1275 1238

1345 1367 1329

1441 1478 1432

20 55 90 125 160

[∘C]Temperature









1600153

144

135

126

117

108

99

90

81

72

63

54

45

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

5445

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

54

45

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

5445

36

27200∘C



450

550

650

750

28 mm

32 mm

38 mm

42 mm ∘C

∘C

∘C

∘C


1408

1325

1213

1120

70 mm

64 mm

62 mm

52 mm ∘C

∘C

∘C

∘C






1

0 30 30 30 302 992 1002 1012 10224 1186 1199 1201 12116 1164 1234 1242 12568 1111 1215 1326 133510 1070 1180 1295 142312 1155 1267 140814 1220 137216 1330

2

0 30 30 30 302 1012 1021 1033 10424 1206 1219 1222 12366 1185 1255 1266 12728 1167 1244 1347 135110 1121 1219 1324 145812 1184 1302 144214 1251 141616 1381

3

0 30 30 30 302 992 1003 1012 10234 1162 1175 1183 11996 1141 1224 1234 12488 1104 1201 1305 131110 1056 1172 1289 141412 1132 1257 138314 1211 134516 1311


Rib

heig

ht (m

m)

ABS material

Rib 1Rib 2

75

70

65

60

55

50

45

40

35

30

25

2035 45 55 65 75 110 120 130 140 150





Data Availability







Acknowledgments


References





















Advances in



Journal of

Chemistry















Journal of





Volume 2018









Journal of


Na

nom

ate

ria

ls









Hot air gates

Middle plate

Heater hole

Air inlet


RunnerGate entrance

Cavity insert

Cavity







A A


A - AR4 B

12032 3 O

O005O005

B101

R2

R2

95465

4 6

19000-02

17500500

600 -001

1200 -001

1200 -001

1800 -001

0200-01

(a)

(b)


Ex-GMTC controller

Hot gasgates

Coreplate

position

Cavityplate

position

Robot arm






Heating surface

Cooling channel

Gas drier

`

P1

P2

P3

P4

Cavity insert

12

10


000 10000

150005000

20000 (mm)

(c) Meshing model


Thin rib

Melt entrance

Rib 1

03

80

05

R520

252 7

Rib 2








5

P1 623 732 833 925 1028P2 581 693 814 845 954P3 566 672 798 824 913P4 578 660 789 766 884

10

P1 760 916 1091 1158 1256P2 783 926 1095 1155 1268P3 745 844 1056 1043 1157P4 744 868 1044 1051 1156

15

P1 908 1057 1190 1318 1484P2 872 1027 1175 1237 1442P3 866 1015 1163 1242 1421P4 855 1013 1154 1310 1416

20

P1 922 1140 1256 1478 1548P2 902 1109 1229 1466 1537P3 883 1081 1197 1459 1511P4 848 1053 1171 1459 1505

25

P1 956 1162 1298 1474 1601P2 921 1124 1255 1440 1586P3 912 1126 1233 1421 1578P4 866 968 1174 1438 1557

30

P1 965 1196 1329 1517 1613P2 944 1177 1280 1479 1594P3 943 1169 1274 1453 1581P4 840 1062 1196 1407 1525










Cooling channels

Heating area

Cavity area


1 2 3




Cavity insert

Insert cover

Insert block

Cooling channel

Heating surface

Micro rib


B

B





10s

40 72 105 138 170

15s

20s

25s

30s

5s

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]



30 s

25 s

20 s

15 s

10 s

5 s


40 72 105 138 170

Temperature [∘C]





0 5 10 15 20 25 30

Heating time (s)


180

160

140

120

100

80

60

40

20



Tem

pera

ture

(∘C)




0 5 10 15 20 25 30

Heating time (s)

180

160

140

120

100

80

60

40

20

Tem

pera

ture

(∘C)





0 5 10 15 20 25 30

Heating time (s)

180

160

140

120

100

80

60

40

20

Tem

pera

ture

(∘C)





0 5 10 15 20 25 30

Heating time (s)

180

160

140

120

100

80

60

40

20

Tem

pera

ture

(∘C)









654

688

701

662

604

625

631

651


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C


956

995

1001

962

926

957

960

954


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C


1258

1285

1304

1270

1185

1198

1201

1265


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C


1354

1358

1367

1380

1289

1305

1308

1337


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C



Heating time20 s

Heating time15 s

Heating time10 s

Heating time 5 s

Without heating

02 mm thickness

3785 mm

04 mm thickness

7468 mm 11641 mm

3836 mm 7777 mm 12097 mm

3896 mm 7854 mm 12335 mm

4024 mm 8185 mm 13290 mm






Heating time20 s

Heating time15 s

Heating time10 s

Heating time5 s

Without heating

02 mm thickness

1454 mm

04 mm thickness

2556 mm

1469 mm 2647 mm

1485 mm 2686 mm

1526 mm 2789 mm

1580 mm 3024 mm

3604 mm

3741 mm

3809 mm

4011 mm



Heating time

Without heating

5 s 10 s 15 s 20 s

02 mm04 mm06 mm

im

prov

emen

t

25

20

15

0

5

10

(a) PP material

im

prov

emen

t

Without heating

5 s 10 s 15 s 20 s

Heating time

25

20

15

0

5

10

02 mm04 mm06 mm

(b) ABS material







Time (s)

End of heating step




Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(a)


End of heating step



Time (s)


Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(b)


End of heating step



Time (s)


Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(c)


Time (s)

End of heating step




Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(d)




4 Conclusions



Heating time 10 s

Heating time 8 s

Heating time 6 s

Heating time 4 s

1208 1237 1189

1256 1275 1238

1345 1367 1329

1441 1478 1432

20 55 90 125 160

[∘C]Temperature









1600153

144

135

126

117

108

99

90

81

72

63

54

45

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

5445

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

54

45

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

5445

36

27200∘C



450

550

650

750

28 mm

32 mm

38 mm

42 mm ∘C

∘C

∘C

∘C


1408

1325

1213

1120

70 mm

64 mm

62 mm

52 mm ∘C

∘C

∘C

∘C






1

0 30 30 30 302 992 1002 1012 10224 1186 1199 1201 12116 1164 1234 1242 12568 1111 1215 1326 133510 1070 1180 1295 142312 1155 1267 140814 1220 137216 1330

2

0 30 30 30 302 1012 1021 1033 10424 1206 1219 1222 12366 1185 1255 1266 12728 1167 1244 1347 135110 1121 1219 1324 145812 1184 1302 144214 1251 141616 1381

3

0 30 30 30 302 992 1003 1012 10234 1162 1175 1183 11996 1141 1224 1234 12488 1104 1201 1305 131110 1056 1172 1289 141412 1132 1257 138314 1211 134516 1311


Rib

heig

ht (m

m)

ABS material

Rib 1Rib 2

75

70

65

60

55

50

45

40

35

30

25

2035 45 55 65 75 110 120 130 140 150





Data Availability







Acknowledgments


References





















Advances in



Journal of

Chemistry















Journal of





Volume 2018









Journal of


Na

nom

ate

ria

ls





A A


A - AR4 B

12032 3 O

O005O005

B101

R2

R2

95465

4 6

19000-02

17500500

600 -001

1200 -001

1200 -001

1800 -001

0200-01

(a)

(b)


Ex-GMTC controller

Hot gasgates

Coreplate

position

Cavityplate

position

Robot arm






Heating surface

Cooling channel

Gas drier

`

P1

P2

P3

P4

Cavity insert

12

10


000 10000

150005000

20000 (mm)

(c) Meshing model


Thin rib

Melt entrance

Rib 1

03

80

05

R520

252 7

Rib 2








5

P1 623 732 833 925 1028P2 581 693 814 845 954P3 566 672 798 824 913P4 578 660 789 766 884

10

P1 760 916 1091 1158 1256P2 783 926 1095 1155 1268P3 745 844 1056 1043 1157P4 744 868 1044 1051 1156

15

P1 908 1057 1190 1318 1484P2 872 1027 1175 1237 1442P3 866 1015 1163 1242 1421P4 855 1013 1154 1310 1416

20

P1 922 1140 1256 1478 1548P2 902 1109 1229 1466 1537P3 883 1081 1197 1459 1511P4 848 1053 1171 1459 1505

25

P1 956 1162 1298 1474 1601P2 921 1124 1255 1440 1586P3 912 1126 1233 1421 1578P4 866 968 1174 1438 1557

30

P1 965 1196 1329 1517 1613P2 944 1177 1280 1479 1594P3 943 1169 1274 1453 1581P4 840 1062 1196 1407 1525










Cooling channels

Heating area

Cavity area


1 2 3




Cavity insert

Insert cover

Insert block

Cooling channel

Heating surface

Micro rib


B

B





10s

40 72 105 138 170

15s

20s

25s

30s

5s

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]



30 s

25 s

20 s

15 s

10 s

5 s


40 72 105 138 170

Temperature [∘C]





0 5 10 15 20 25 30

Heating time (s)


180

160

140

120

100

80

60

40

20



Tem

pera

ture

(∘C)




0 5 10 15 20 25 30

Heating time (s)

180

160

140

120

100

80

60

40

20

Tem

pera

ture

(∘C)





0 5 10 15 20 25 30

Heating time (s)

180

160

140

120

100

80

60

40

20

Tem

pera

ture

(∘C)





0 5 10 15 20 25 30

Heating time (s)

180

160

140

120

100

80

60

40

20

Tem

pera

ture

(∘C)









654

688

701

662

604

625

631

651


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C


956

995

1001

962

926

957

960

954


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C


1258

1285

1304

1270

1185

1198

1201

1265


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C


1354

1358

1367

1380

1289

1305

1308

1337


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C



Heating time20 s

Heating time15 s

Heating time10 s

Heating time 5 s

Without heating

02 mm thickness

3785 mm

04 mm thickness

7468 mm 11641 mm

3836 mm 7777 mm 12097 mm

3896 mm 7854 mm 12335 mm

4024 mm 8185 mm 13290 mm






Heating time20 s

Heating time15 s

Heating time10 s

Heating time5 s

Without heating

02 mm thickness

1454 mm

04 mm thickness

2556 mm

1469 mm 2647 mm

1485 mm 2686 mm

1526 mm 2789 mm

1580 mm 3024 mm

3604 mm

3741 mm

3809 mm

4011 mm



Heating time

Without heating

5 s 10 s 15 s 20 s

02 mm04 mm06 mm

im

prov

emen

t

25

20

15

0

5

10

(a) PP material

im

prov

emen

t

Without heating

5 s 10 s 15 s 20 s

Heating time

25

20

15

0

5

10

02 mm04 mm06 mm

(b) ABS material







Time (s)

End of heating step




Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(a)


End of heating step



Time (s)


Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(b)


End of heating step



Time (s)


Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(c)


Time (s)

End of heating step




Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(d)




4 Conclusions



Heating time 10 s

Heating time 8 s

Heating time 6 s

Heating time 4 s

1208 1237 1189

1256 1275 1238

1345 1367 1329

1441 1478 1432

20 55 90 125 160

[∘C]Temperature









1600153

144

135

126

117

108

99

90

81

72

63

54

45

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

5445

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

54

45

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

5445

36

27200∘C



450

550

650

750

28 mm

32 mm

38 mm

42 mm ∘C

∘C

∘C

∘C


1408

1325

1213

1120

70 mm

64 mm

62 mm

52 mm ∘C

∘C

∘C

∘C






1

0 30 30 30 302 992 1002 1012 10224 1186 1199 1201 12116 1164 1234 1242 12568 1111 1215 1326 133510 1070 1180 1295 142312 1155 1267 140814 1220 137216 1330

2

0 30 30 30 302 1012 1021 1033 10424 1206 1219 1222 12366 1185 1255 1266 12728 1167 1244 1347 135110 1121 1219 1324 145812 1184 1302 144214 1251 141616 1381

3

0 30 30 30 302 992 1003 1012 10234 1162 1175 1183 11996 1141 1224 1234 12488 1104 1201 1305 131110 1056 1172 1289 141412 1132 1257 138314 1211 134516 1311


Rib

heig

ht (m

m)

ABS material

Rib 1Rib 2

75

70

65

60

55

50

45

40

35

30

25

2035 45 55 65 75 110 120 130 140 150





Data Availability







Acknowledgments


References





















Advances in



Journal of

Chemistry















Journal of





Volume 2018









Journal of


Na

nom

ate

ria

ls





Heating surface

Cooling channel

Gas drier

`

P1

P2

P3

P4

Cavity insert

12

10


000 10000

150005000

20000 (mm)

(c) Meshing model


Thin rib

Melt entrance

Rib 1

03

80

05

R520

252 7

Rib 2








5

P1 623 732 833 925 1028P2 581 693 814 845 954P3 566 672 798 824 913P4 578 660 789 766 884

10

P1 760 916 1091 1158 1256P2 783 926 1095 1155 1268P3 745 844 1056 1043 1157P4 744 868 1044 1051 1156

15

P1 908 1057 1190 1318 1484P2 872 1027 1175 1237 1442P3 866 1015 1163 1242 1421P4 855 1013 1154 1310 1416

20

P1 922 1140 1256 1478 1548P2 902 1109 1229 1466 1537P3 883 1081 1197 1459 1511P4 848 1053 1171 1459 1505

25

P1 956 1162 1298 1474 1601P2 921 1124 1255 1440 1586P3 912 1126 1233 1421 1578P4 866 968 1174 1438 1557

30

P1 965 1196 1329 1517 1613P2 944 1177 1280 1479 1594P3 943 1169 1274 1453 1581P4 840 1062 1196 1407 1525










Cooling channels

Heating area

Cavity area


1 2 3




Cavity insert

Insert cover

Insert block

Cooling channel

Heating surface

Micro rib


B

B





10s

40 72 105 138 170

15s

20s

25s

30s

5s

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]



30 s

25 s

20 s

15 s

10 s

5 s


40 72 105 138 170

Temperature [∘C]





0 5 10 15 20 25 30

Heating time (s)


180

160

140

120

100

80

60

40

20



Tem

pera

ture

(∘C)




0 5 10 15 20 25 30

Heating time (s)

180

160

140

120

100

80

60

40

20

Tem

pera

ture

(∘C)





0 5 10 15 20 25 30

Heating time (s)

180

160

140

120

100

80

60

40

20

Tem

pera

ture

(∘C)





0 5 10 15 20 25 30

Heating time (s)

180

160

140

120

100

80

60

40

20

Tem

pera

ture

(∘C)









654

688

701

662

604

625

631

651


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C


956

995

1001

962

926

957

960

954


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C


1258

1285

1304

1270

1185

1198

1201

1265


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C


1354

1358

1367

1380

1289

1305

1308

1337


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C



Heating time20 s

Heating time15 s

Heating time10 s

Heating time 5 s

Without heating

02 mm thickness

3785 mm

04 mm thickness

7468 mm 11641 mm

3836 mm 7777 mm 12097 mm

3896 mm 7854 mm 12335 mm

4024 mm 8185 mm 13290 mm






Heating time20 s

Heating time15 s

Heating time10 s

Heating time5 s

Without heating

02 mm thickness

1454 mm

04 mm thickness

2556 mm

1469 mm 2647 mm

1485 mm 2686 mm

1526 mm 2789 mm

1580 mm 3024 mm

3604 mm

3741 mm

3809 mm

4011 mm



Heating time

Without heating

5 s 10 s 15 s 20 s

02 mm04 mm06 mm

im

prov

emen

t

25

20

15

0

5

10

(a) PP material

im

prov

emen

t

Without heating

5 s 10 s 15 s 20 s

Heating time

25

20

15

0

5

10

02 mm04 mm06 mm

(b) ABS material







Time (s)

End of heating step




Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(a)


End of heating step



Time (s)


Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(b)


End of heating step



Time (s)


Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(c)


Time (s)

End of heating step




Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(d)




4 Conclusions



Heating time 10 s

Heating time 8 s

Heating time 6 s

Heating time 4 s

1208 1237 1189

1256 1275 1238

1345 1367 1329

1441 1478 1432

20 55 90 125 160

[∘C]Temperature









1600153

144

135

126

117

108

99

90

81

72

63

54

45

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

5445

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

54

45

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

5445

36

27200∘C



450

550

650

750

28 mm

32 mm

38 mm

42 mm ∘C

∘C

∘C

∘C


1408

1325

1213

1120

70 mm

64 mm

62 mm

52 mm ∘C

∘C

∘C

∘C






1

0 30 30 30 302 992 1002 1012 10224 1186 1199 1201 12116 1164 1234 1242 12568 1111 1215 1326 133510 1070 1180 1295 142312 1155 1267 140814 1220 137216 1330

2

0 30 30 30 302 1012 1021 1033 10424 1206 1219 1222 12366 1185 1255 1266 12728 1167 1244 1347 135110 1121 1219 1324 145812 1184 1302 144214 1251 141616 1381

3

0 30 30 30 302 992 1003 1012 10234 1162 1175 1183 11996 1141 1224 1234 12488 1104 1201 1305 131110 1056 1172 1289 141412 1132 1257 138314 1211 134516 1311


Rib

heig

ht (m

m)

ABS material

Rib 1Rib 2

75

70

65

60

55

50

45

40

35

30

25

2035 45 55 65 75 110 120 130 140 150





Data Availability







Acknowledgments


References





















Advances in



Journal of

Chemistry















Journal of





Volume 2018









Journal of


Na

nom

ate

ria

ls







5

P1 623 732 833 925 1028P2 581 693 814 845 954P3 566 672 798 824 913P4 578 660 789 766 884

10

P1 760 916 1091 1158 1256P2 783 926 1095 1155 1268P3 745 844 1056 1043 1157P4 744 868 1044 1051 1156

15

P1 908 1057 1190 1318 1484P2 872 1027 1175 1237 1442P3 866 1015 1163 1242 1421P4 855 1013 1154 1310 1416

20

P1 922 1140 1256 1478 1548P2 902 1109 1229 1466 1537P3 883 1081 1197 1459 1511P4 848 1053 1171 1459 1505

25

P1 956 1162 1298 1474 1601P2 921 1124 1255 1440 1586P3 912 1126 1233 1421 1578P4 866 968 1174 1438 1557

30

P1 965 1196 1329 1517 1613P2 944 1177 1280 1479 1594P3 943 1169 1274 1453 1581P4 840 1062 1196 1407 1525










Cooling channels

Heating area

Cavity area


1 2 3




Cavity insert

Insert cover

Insert block

Cooling channel

Heating surface

Micro rib


B

B





10s

40 72 105 138 170

15s

20s

25s

30s

5s

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]



30 s

25 s

20 s

15 s

10 s

5 s


40 72 105 138 170

Temperature [∘C]





0 5 10 15 20 25 30

Heating time (s)


180

160

140

120

100

80

60

40

20



Tem

pera

ture

(∘C)




0 5 10 15 20 25 30

Heating time (s)

180

160

140

120

100

80

60

40

20

Tem

pera

ture

(∘C)





0 5 10 15 20 25 30

Heating time (s)

180

160

140

120

100

80

60

40

20

Tem

pera

ture

(∘C)





0 5 10 15 20 25 30

Heating time (s)

180

160

140

120

100

80

60

40

20

Tem

pera

ture

(∘C)









654

688

701

662

604

625

631

651


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C


956

995

1001

962

926

957

960

954


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C


1258

1285

1304

1270

1185

1198

1201

1265


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C


1354

1358

1367

1380

1289

1305

1308

1337


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C



Heating time20 s

Heating time15 s

Heating time10 s

Heating time 5 s

Without heating

02 mm thickness

3785 mm

04 mm thickness

7468 mm 11641 mm

3836 mm 7777 mm 12097 mm

3896 mm 7854 mm 12335 mm

4024 mm 8185 mm 13290 mm






Heating time20 s

Heating time15 s

Heating time10 s

Heating time5 s

Without heating

02 mm thickness

1454 mm

04 mm thickness

2556 mm

1469 mm 2647 mm

1485 mm 2686 mm

1526 mm 2789 mm

1580 mm 3024 mm

3604 mm

3741 mm

3809 mm

4011 mm



Heating time

Without heating

5 s 10 s 15 s 20 s

02 mm04 mm06 mm

im

prov

emen

t

25

20

15

0

5

10

(a) PP material

im

prov

emen

t

Without heating

5 s 10 s 15 s 20 s

Heating time

25

20

15

0

5

10

02 mm04 mm06 mm

(b) ABS material







Time (s)

End of heating step




Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(a)


End of heating step



Time (s)


Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(b)


End of heating step



Time (s)


Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(c)


Time (s)

End of heating step




Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(d)




4 Conclusions



Heating time 10 s

Heating time 8 s

Heating time 6 s

Heating time 4 s

1208 1237 1189

1256 1275 1238

1345 1367 1329

1441 1478 1432

20 55 90 125 160

[∘C]Temperature









1600153

144

135

126

117

108

99

90

81

72

63

54

45

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

5445

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

54

45

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

5445

36

27200∘C



450

550

650

750

28 mm

32 mm

38 mm

42 mm ∘C

∘C

∘C

∘C


1408

1325

1213

1120

70 mm

64 mm

62 mm

52 mm ∘C

∘C

∘C

∘C






1

0 30 30 30 302 992 1002 1012 10224 1186 1199 1201 12116 1164 1234 1242 12568 1111 1215 1326 133510 1070 1180 1295 142312 1155 1267 140814 1220 137216 1330

2

0 30 30 30 302 1012 1021 1033 10424 1206 1219 1222 12366 1185 1255 1266 12728 1167 1244 1347 135110 1121 1219 1324 145812 1184 1302 144214 1251 141616 1381

3

0 30 30 30 302 992 1003 1012 10234 1162 1175 1183 11996 1141 1224 1234 12488 1104 1201 1305 131110 1056 1172 1289 141412 1132 1257 138314 1211 134516 1311


Rib

heig

ht (m

m)

ABS material

Rib 1Rib 2

75

70

65

60

55

50

45

40

35

30

25

2035 45 55 65 75 110 120 130 140 150





Data Availability







Acknowledgments


References





















Advances in



Journal of

Chemistry















Journal of





Volume 2018









Journal of


Na

nom

ate

ria

ls









Cooling channels

Heating area

Cavity area


1 2 3




Cavity insert

Insert cover

Insert block

Cooling channel

Heating surface

Micro rib


B

B





10s

40 72 105 138 170

15s

20s

25s

30s

5s

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]



30 s

25 s

20 s

15 s

10 s

5 s


40 72 105 138 170

Temperature [∘C]





0 5 10 15 20 25 30

Heating time (s)


180

160

140

120

100

80

60

40

20



Tem

pera

ture

(∘C)




0 5 10 15 20 25 30

Heating time (s)

180

160

140

120

100

80

60

40

20

Tem

pera

ture

(∘C)





0 5 10 15 20 25 30

Heating time (s)

180

160

140

120

100

80

60

40

20

Tem

pera

ture

(∘C)





0 5 10 15 20 25 30

Heating time (s)

180

160

140

120

100

80

60

40

20

Tem

pera

ture

(∘C)









654

688

701

662

604

625

631

651


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C


956

995

1001

962

926

957

960

954


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C


1258

1285

1304

1270

1185

1198

1201

1265


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C


1354

1358

1367

1380

1289

1305

1308

1337


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C



Heating time20 s

Heating time15 s

Heating time10 s

Heating time 5 s

Without heating

02 mm thickness

3785 mm

04 mm thickness

7468 mm 11641 mm

3836 mm 7777 mm 12097 mm

3896 mm 7854 mm 12335 mm

4024 mm 8185 mm 13290 mm






Heating time20 s

Heating time15 s

Heating time10 s

Heating time5 s

Without heating

02 mm thickness

1454 mm

04 mm thickness

2556 mm

1469 mm 2647 mm

1485 mm 2686 mm

1526 mm 2789 mm

1580 mm 3024 mm

3604 mm

3741 mm

3809 mm

4011 mm



Heating time

Without heating

5 s 10 s 15 s 20 s

02 mm04 mm06 mm

im

prov

emen

t

25

20

15

0

5

10

(a) PP material

im

prov

emen

t

Without heating

5 s 10 s 15 s 20 s

Heating time

25

20

15

0

5

10

02 mm04 mm06 mm

(b) ABS material







Time (s)

End of heating step




Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(a)


End of heating step



Time (s)


Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(b)


End of heating step



Time (s)


Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(c)


Time (s)

End of heating step




Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(d)




4 Conclusions



Heating time 10 s

Heating time 8 s

Heating time 6 s

Heating time 4 s

1208 1237 1189

1256 1275 1238

1345 1367 1329

1441 1478 1432

20 55 90 125 160

[∘C]Temperature









1600153

144

135

126

117

108

99

90

81

72

63

54

45

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

5445

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

54

45

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

5445

36

27200∘C



450

550

650

750

28 mm

32 mm

38 mm

42 mm ∘C

∘C

∘C

∘C


1408

1325

1213

1120

70 mm

64 mm

62 mm

52 mm ∘C

∘C

∘C

∘C






1

0 30 30 30 302 992 1002 1012 10224 1186 1199 1201 12116 1164 1234 1242 12568 1111 1215 1326 133510 1070 1180 1295 142312 1155 1267 140814 1220 137216 1330

2

0 30 30 30 302 1012 1021 1033 10424 1206 1219 1222 12366 1185 1255 1266 12728 1167 1244 1347 135110 1121 1219 1324 145812 1184 1302 144214 1251 141616 1381

3

0 30 30 30 302 992 1003 1012 10234 1162 1175 1183 11996 1141 1224 1234 12488 1104 1201 1305 131110 1056 1172 1289 141412 1132 1257 138314 1211 134516 1311


Rib

heig

ht (m

m)

ABS material

Rib 1Rib 2

75

70

65

60

55

50

45

40

35

30

25

2035 45 55 65 75 110 120 130 140 150





Data Availability







Acknowledgments


References





















Advances in



Journal of

Chemistry















Journal of





Volume 2018









Journal of


Na

nom

ate

ria

ls





10s

40 72 105 138 170

15s

20s

25s

30s

5s

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]


10s

15s

20s

25s

30s

5s40 72 105 138 170

Temperature [∘C]



30 s

25 s

20 s

15 s

10 s

5 s


40 72 105 138 170

Temperature [∘C]





0 5 10 15 20 25 30

Heating time (s)


180

160

140

120

100

80

60

40

20



Tem

pera

ture

(∘C)




0 5 10 15 20 25 30

Heating time (s)

180

160

140

120

100

80

60

40

20

Tem

pera

ture

(∘C)





0 5 10 15 20 25 30

Heating time (s)

180

160

140

120

100

80

60

40

20

Tem

pera

ture

(∘C)





0 5 10 15 20 25 30

Heating time (s)

180

160

140

120

100

80

60

40

20

Tem

pera

ture

(∘C)









654

688

701

662

604

625

631

651


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C


956

995

1001

962

926

957

960

954


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C


1258

1285

1304

1270

1185

1198

1201

1265


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C


1354

1358

1367

1380

1289

1305

1308

1337


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C



Heating time20 s

Heating time15 s

Heating time10 s

Heating time 5 s

Without heating

02 mm thickness

3785 mm

04 mm thickness

7468 mm 11641 mm

3836 mm 7777 mm 12097 mm

3896 mm 7854 mm 12335 mm

4024 mm 8185 mm 13290 mm






Heating time20 s

Heating time15 s

Heating time10 s

Heating time5 s

Without heating

02 mm thickness

1454 mm

04 mm thickness

2556 mm

1469 mm 2647 mm

1485 mm 2686 mm

1526 mm 2789 mm

1580 mm 3024 mm

3604 mm

3741 mm

3809 mm

4011 mm



Heating time

Without heating

5 s 10 s 15 s 20 s

02 mm04 mm06 mm

im

prov

emen

t

25

20

15

0

5

10

(a) PP material

im

prov

emen

t

Without heating

5 s 10 s 15 s 20 s

Heating time

25

20

15

0

5

10

02 mm04 mm06 mm

(b) ABS material







Time (s)

End of heating step




Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(a)


End of heating step



Time (s)


Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(b)


End of heating step



Time (s)


Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(c)


Time (s)

End of heating step




Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(d)




4 Conclusions



Heating time 10 s

Heating time 8 s

Heating time 6 s

Heating time 4 s

1208 1237 1189

1256 1275 1238

1345 1367 1329

1441 1478 1432

20 55 90 125 160

[∘C]Temperature









1600153

144

135

126

117

108

99

90

81

72

63

54

45

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

5445

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

54

45

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

5445

36

27200∘C



450

550

650

750

28 mm

32 mm

38 mm

42 mm ∘C

∘C

∘C

∘C


1408

1325

1213

1120

70 mm

64 mm

62 mm

52 mm ∘C

∘C

∘C

∘C






1

0 30 30 30 302 992 1002 1012 10224 1186 1199 1201 12116 1164 1234 1242 12568 1111 1215 1326 133510 1070 1180 1295 142312 1155 1267 140814 1220 137216 1330

2

0 30 30 30 302 1012 1021 1033 10424 1206 1219 1222 12366 1185 1255 1266 12728 1167 1244 1347 135110 1121 1219 1324 145812 1184 1302 144214 1251 141616 1381

3

0 30 30 30 302 992 1003 1012 10234 1162 1175 1183 11996 1141 1224 1234 12488 1104 1201 1305 131110 1056 1172 1289 141412 1132 1257 138314 1211 134516 1311


Rib

heig

ht (m

m)

ABS material

Rib 1Rib 2

75

70

65

60

55

50

45

40

35

30

25

2035 45 55 65 75 110 120 130 140 150





Data Availability







Acknowledgments


References





















Advances in



Journal of

Chemistry















Journal of





Volume 2018









Journal of


Na

nom

ate

ria

ls





0 5 10 15 20 25 30

Heating time (s)


180

160

140

120

100

80

60

40

20



Tem

pera

ture

(∘C)




0 5 10 15 20 25 30

Heating time (s)

180

160

140

120

100

80

60

40

20

Tem

pera

ture

(∘C)





0 5 10 15 20 25 30

Heating time (s)

180

160

140

120

100

80

60

40

20

Tem

pera

ture

(∘C)





0 5 10 15 20 25 30

Heating time (s)

180

160

140

120

100

80

60

40

20

Tem

pera

ture

(∘C)









654

688

701

662

604

625

631

651


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C


956

995

1001

962

926

957

960

954


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C


1258

1285

1304

1270

1185

1198

1201

1265


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C


1354

1358

1367

1380

1289

1305

1308

1337


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C



Heating time20 s

Heating time15 s

Heating time10 s

Heating time 5 s

Without heating

02 mm thickness

3785 mm

04 mm thickness

7468 mm 11641 mm

3836 mm 7777 mm 12097 mm

3896 mm 7854 mm 12335 mm

4024 mm 8185 mm 13290 mm






Heating time20 s

Heating time15 s

Heating time10 s

Heating time5 s

Without heating

02 mm thickness

1454 mm

04 mm thickness

2556 mm

1469 mm 2647 mm

1485 mm 2686 mm

1526 mm 2789 mm

1580 mm 3024 mm

3604 mm

3741 mm

3809 mm

4011 mm



Heating time

Without heating

5 s 10 s 15 s 20 s

02 mm04 mm06 mm

im

prov

emen

t

25

20

15

0

5

10

(a) PP material

im

prov

emen

t

Without heating

5 s 10 s 15 s 20 s

Heating time

25

20

15

0

5

10

02 mm04 mm06 mm

(b) ABS material







Time (s)

End of heating step




Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(a)


End of heating step



Time (s)


Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(b)


End of heating step



Time (s)


Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(c)


Time (s)

End of heating step




Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(d)




4 Conclusions



Heating time 10 s

Heating time 8 s

Heating time 6 s

Heating time 4 s

1208 1237 1189

1256 1275 1238

1345 1367 1329

1441 1478 1432

20 55 90 125 160

[∘C]Temperature









1600153

144

135

126

117

108

99

90

81

72

63

54

45

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

5445

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

54

45

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

5445

36

27200∘C



450

550

650

750

28 mm

32 mm

38 mm

42 mm ∘C

∘C

∘C

∘C


1408

1325

1213

1120

70 mm

64 mm

62 mm

52 mm ∘C

∘C

∘C

∘C






1

0 30 30 30 302 992 1002 1012 10224 1186 1199 1201 12116 1164 1234 1242 12568 1111 1215 1326 133510 1070 1180 1295 142312 1155 1267 140814 1220 137216 1330

2

0 30 30 30 302 1012 1021 1033 10424 1206 1219 1222 12366 1185 1255 1266 12728 1167 1244 1347 135110 1121 1219 1324 145812 1184 1302 144214 1251 141616 1381

3

0 30 30 30 302 992 1003 1012 10234 1162 1175 1183 11996 1141 1224 1234 12488 1104 1201 1305 131110 1056 1172 1289 141412 1132 1257 138314 1211 134516 1311


Rib

heig

ht (m

m)

ABS material

Rib 1Rib 2

75

70

65

60

55

50

45

40

35

30

25

2035 45 55 65 75 110 120 130 140 150





Data Availability







Acknowledgments


References





















Advances in



Journal of

Chemistry















Journal of





Volume 2018









Journal of


Na

nom

ate

ria

ls





654

688

701

662

604

625

631

651


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C


956

995

1001

962

926

957

960

954


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C


1258

1285

1304

1270

1185

1198

1201

1265


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C


1354

1358

1367

1380

1289

1305

1308

1337


170

138

105

72

40

1700

162

153

144

135

126

117

108

99

90

81

72

63

54

45400∘C



Heating time20 s

Heating time15 s

Heating time10 s

Heating time 5 s

Without heating

02 mm thickness

3785 mm

04 mm thickness

7468 mm 11641 mm

3836 mm 7777 mm 12097 mm

3896 mm 7854 mm 12335 mm

4024 mm 8185 mm 13290 mm






Heating time20 s

Heating time15 s

Heating time10 s

Heating time5 s

Without heating

02 mm thickness

1454 mm

04 mm thickness

2556 mm

1469 mm 2647 mm

1485 mm 2686 mm

1526 mm 2789 mm

1580 mm 3024 mm

3604 mm

3741 mm

3809 mm

4011 mm



Heating time

Without heating

5 s 10 s 15 s 20 s

02 mm04 mm06 mm

im

prov

emen

t

25

20

15

0

5

10

(a) PP material

im

prov

emen

t

Without heating

5 s 10 s 15 s 20 s

Heating time

25

20

15

0

5

10

02 mm04 mm06 mm

(b) ABS material







Time (s)

End of heating step




Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(a)


End of heating step



Time (s)


Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(b)


End of heating step



Time (s)


Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(c)


Time (s)

End of heating step




Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(d)




4 Conclusions



Heating time 10 s

Heating time 8 s

Heating time 6 s

Heating time 4 s

1208 1237 1189

1256 1275 1238

1345 1367 1329

1441 1478 1432

20 55 90 125 160

[∘C]Temperature









1600153

144

135

126

117

108

99

90

81

72

63

54

45

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

5445

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

54

45

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

5445

36

27200∘C



450

550

650

750

28 mm

32 mm

38 mm

42 mm ∘C

∘C

∘C

∘C


1408

1325

1213

1120

70 mm

64 mm

62 mm

52 mm ∘C

∘C

∘C

∘C






1

0 30 30 30 302 992 1002 1012 10224 1186 1199 1201 12116 1164 1234 1242 12568 1111 1215 1326 133510 1070 1180 1295 142312 1155 1267 140814 1220 137216 1330

2

0 30 30 30 302 1012 1021 1033 10424 1206 1219 1222 12366 1185 1255 1266 12728 1167 1244 1347 135110 1121 1219 1324 145812 1184 1302 144214 1251 141616 1381

3

0 30 30 30 302 992 1003 1012 10234 1162 1175 1183 11996 1141 1224 1234 12488 1104 1201 1305 131110 1056 1172 1289 141412 1132 1257 138314 1211 134516 1311


Rib

heig

ht (m

m)

ABS material

Rib 1Rib 2

75

70

65

60

55

50

45

40

35

30

25

2035 45 55 65 75 110 120 130 140 150





Data Availability







Acknowledgments


References





















Advances in



Journal of

Chemistry















Journal of





Volume 2018









Journal of


Na

nom

ate

ria

ls





Heating time20 s

Heating time15 s

Heating time10 s

Heating time5 s

Without heating

02 mm thickness

1454 mm

04 mm thickness

2556 mm

1469 mm 2647 mm

1485 mm 2686 mm

1526 mm 2789 mm

1580 mm 3024 mm

3604 mm

3741 mm

3809 mm

4011 mm



Heating time

Without heating

5 s 10 s 15 s 20 s

02 mm04 mm06 mm

im

prov

emen

t

25

20

15

0

5

10

(a) PP material

im

prov

emen

t

Without heating

5 s 10 s 15 s 20 s

Heating time

25

20

15

0

5

10

02 mm04 mm06 mm

(b) ABS material







Time (s)

End of heating step




Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(a)


End of heating step



Time (s)


Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(b)


End of heating step



Time (s)


Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(c)


Time (s)

End of heating step




Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(d)




4 Conclusions



Heating time 10 s

Heating time 8 s

Heating time 6 s

Heating time 4 s

1208 1237 1189

1256 1275 1238

1345 1367 1329

1441 1478 1432

20 55 90 125 160

[∘C]Temperature









1600153

144

135

126

117

108

99

90

81

72

63

54

45

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

5445

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

54

45

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

5445

36

27200∘C



450

550

650

750

28 mm

32 mm

38 mm

42 mm ∘C

∘C

∘C

∘C


1408

1325

1213

1120

70 mm

64 mm

62 mm

52 mm ∘C

∘C

∘C

∘C






1

0 30 30 30 302 992 1002 1012 10224 1186 1199 1201 12116 1164 1234 1242 12568 1111 1215 1326 133510 1070 1180 1295 142312 1155 1267 140814 1220 137216 1330

2

0 30 30 30 302 1012 1021 1033 10424 1206 1219 1222 12366 1185 1255 1266 12728 1167 1244 1347 135110 1121 1219 1324 145812 1184 1302 144214 1251 141616 1381

3

0 30 30 30 302 992 1003 1012 10234 1162 1175 1183 11996 1141 1224 1234 12488 1104 1201 1305 131110 1056 1172 1289 141412 1132 1257 138314 1211 134516 1311


Rib

heig

ht (m

m)

ABS material

Rib 1Rib 2

75

70

65

60

55

50

45

40

35

30

25

2035 45 55 65 75 110 120 130 140 150





Data Availability







Acknowledgments


References





















Advances in



Journal of

Chemistry















Journal of





Volume 2018









Journal of


Na

nom

ate

ria

ls






Time (s)

End of heating step




Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(a)


End of heating step



Time (s)


Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(b)


End of heating step



Time (s)


Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(c)


Time (s)

End of heating step




Tem

pera

ture

(∘C)

160

140

120

100

80

60

40

20

0 2 4 6 8 10 12 14 16

(d)




4 Conclusions



Heating time 10 s

Heating time 8 s

Heating time 6 s

Heating time 4 s

1208 1237 1189

1256 1275 1238

1345 1367 1329

1441 1478 1432

20 55 90 125 160

[∘C]Temperature









1600153

144

135

126

117

108

99

90

81

72

63

54

45

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

5445

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

54

45

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

5445

36

27200∘C



450

550

650

750

28 mm

32 mm

38 mm

42 mm ∘C

∘C

∘C

∘C


1408

1325

1213

1120

70 mm

64 mm

62 mm

52 mm ∘C

∘C

∘C

∘C






1

0 30 30 30 302 992 1002 1012 10224 1186 1199 1201 12116 1164 1234 1242 12568 1111 1215 1326 133510 1070 1180 1295 142312 1155 1267 140814 1220 137216 1330

2

0 30 30 30 302 1012 1021 1033 10424 1206 1219 1222 12366 1185 1255 1266 12728 1167 1244 1347 135110 1121 1219 1324 145812 1184 1302 144214 1251 141616 1381

3

0 30 30 30 302 992 1003 1012 10234 1162 1175 1183 11996 1141 1224 1234 12488 1104 1201 1305 131110 1056 1172 1289 141412 1132 1257 138314 1211 134516 1311


Rib

heig

ht (m

m)

ABS material

Rib 1Rib 2

75

70

65

60

55

50

45

40

35

30

25

2035 45 55 65 75 110 120 130 140 150





Data Availability







Acknowledgments


References





















Advances in



Journal of

Chemistry















Journal of





Volume 2018









Journal of


Na

nom

ate

ria

ls





Heating time 10 s

Heating time 8 s

Heating time 6 s

Heating time 4 s

1208 1237 1189

1256 1275 1238

1345 1367 1329

1441 1478 1432

20 55 90 125 160

[∘C]Temperature









1600153

144

135

126

117

108

99

90

81

72

63

54

45

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

5445

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

54

45

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

5445

36

27200∘C



450

550

650

750

28 mm

32 mm

38 mm

42 mm ∘C

∘C

∘C

∘C


1408

1325

1213

1120

70 mm

64 mm

62 mm

52 mm ∘C

∘C

∘C

∘C






1

0 30 30 30 302 992 1002 1012 10224 1186 1199 1201 12116 1164 1234 1242 12568 1111 1215 1326 133510 1070 1180 1295 142312 1155 1267 140814 1220 137216 1330

2

0 30 30 30 302 1012 1021 1033 10424 1206 1219 1222 12366 1185 1255 1266 12728 1167 1244 1347 135110 1121 1219 1324 145812 1184 1302 144214 1251 141616 1381

3

0 30 30 30 302 992 1003 1012 10234 1162 1175 1183 11996 1141 1224 1234 12488 1104 1201 1305 131110 1056 1172 1289 141412 1132 1257 138314 1211 134516 1311


Rib

heig

ht (m

m)

ABS material

Rib 1Rib 2

75

70

65

60

55

50

45

40

35

30

25

2035 45 55 65 75 110 120 130 140 150





Data Availability







Acknowledgments


References





















Advances in



Journal of

Chemistry















Journal of





Volume 2018









Journal of


Na

nom

ate

ria

ls





1600153

144

135

126

117

108

99

90

81

72

63

54

45

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

5445

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

54

45

36

27200∘C


1600153

144

135

126

117

108

99

90

81

72

63

5445

36

27200∘C



450

550

650

750

28 mm

32 mm

38 mm

42 mm ∘C

∘C

∘C

∘C


1408

1325

1213

1120

70 mm

64 mm

62 mm

52 mm ∘C

∘C

∘C

∘C






1

0 30 30 30 302 992 1002 1012 10224 1186 1199 1201 12116 1164 1234 1242 12568 1111 1215 1326 133510 1070 1180 1295 142312 1155 1267 140814 1220 137216 1330

2

0 30 30 30 302 1012 1021 1033 10424 1206 1219 1222 12366 1185 1255 1266 12728 1167 1244 1347 135110 1121 1219 1324 145812 1184 1302 144214 1251 141616 1381

3

0 30 30 30 302 992 1003 1012 10234 1162 1175 1183 11996 1141 1224 1234 12488 1104 1201 1305 131110 1056 1172 1289 141412 1132 1257 138314 1211 134516 1311


Rib

heig

ht (m

m)

ABS material

Rib 1Rib 2

75

70

65

60

55

50

45

40

35

30

25

2035 45 55 65 75 110 120 130 140 150





Data Availability







Acknowledgments


References





















Advances in



Journal of

Chemistry















Journal of





Volume 2018









Journal of


Na

nom

ate

ria

ls







1

0 30 30 30 302 992 1002 1012 10224 1186 1199 1201 12116 1164 1234 1242 12568 1111 1215 1326 133510 1070 1180 1295 142312 1155 1267 140814 1220 137216 1330

2

0 30 30 30 302 1012 1021 1033 10424 1206 1219 1222 12366 1185 1255 1266 12728 1167 1244 1347 135110 1121 1219 1324 145812 1184 1302 144214 1251 141616 1381

3

0 30 30 30 302 992 1003 1012 10234 1162 1175 1183 11996 1141 1224 1234 12488 1104 1201 1305 131110 1056 1172 1289 141412 1132 1257 138314 1211 134516 1311


Rib

heig

ht (m

m)

ABS material

Rib 1Rib 2

75

70

65

60

55

50

45

40

35

30

25

2035 45 55 65 75 110 120 130 140 150





Data Availability







Acknowledgments


References





















Advances in



Journal of

Chemistry















Journal of





Volume 2018









Journal of


Na

nom

ate

ria

ls





Acknowledgments


References





















Advances in



Journal of

Chemistry















Journal of





Volume 2018









Journal of


Na

nom

ate

ria

ls






Advances in



Journal of

Chemistry















Journal of





Volume 2018









Journal of


Na

nom

ate

ria

ls




Study on External Gas-Assisted Mold Temperature Control...

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