Non-uniform Compensation Technology for Precision Injection Molding Based on High-precision Simulation

YANG Jin; YING Zechen; ZHANG Yun; ZHOU Huamin

doi:10.3969/j.issn.1674-6457.2025.11.001

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Journal of Netshape Forming Engineering ›› 2025, Vol. 17 ›› Issue (11) : 1-12. DOI: 10.3969/j.issn.1674-6457.2025.11.001

Intelligent Processing of Advanced Materials

Non-uniform Compensation Technology for Precision Injection Molding Based on High-precision Simulation

YANG Jin, YING Zechen, ZHANG Yun^*, ZHOU Huamin

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Abstract

The work aims to propose a non-uniform compensation method leveraging high-precision simulation to deal with challenges to the quality compliance of high-precision optical lenses caused by shrinkage and warpage during injection molding. High-precision simulation was achieved by accurately measuring material parameters such as rheology, material properties, and P-V-T (Pressure-Volume-Temperature), as well as calibrating the process settings in the simulation software through sensor deployment. Based on the shrinkage vectors of the contour reference points obtained from the precise simulation, the corresponding reference point coordinates of the mold cavity were calculated, and the cavity parameters were derived through fitting. The compensation amount for each point on the mold contour was computed by comparing the shrinkage differences in the radial and axial directions, thereby realizing non-uniform cavity compensation. The accuracy of the simulation method was verified under multiple process conditions. Results showed that the simulated surface contour was consistent with the measured values, and the average error of the surface simulation could be controlled within 10%. The effect of the non-uniform compensation method was verified via simulation: the surface deviations of the models using the non-uniform compensation method were 0.34 μm and 0.46 μm, which were significantly smaller than those of the uncompensated models (19.89 μm and 7.79 μm) and uniformly compensated models (4.58 μm and 1.31 μm). Two lens mold cores manufactured with the final non-uniform compensation coefficients exhibited surface deviations of 1.210 0 μm/1.418 3 μm and 1.363 1 μm/1.243 8 μm, respectively, meeting the 2 μm error requirement for the T0 phase of lens manufacturing. The results indicate that the proposed simulation calibration approach can effectively improve simulation accuracy. The non-uniform compensation method combined with simulation results not only reduces mold trial costs in the process but also achieves much higher precision than traditional methods, which can meet the accuracy requirements in practical manufacturing.

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precision injection molding / optical lens / simulation / shrinkage compensation / sensor

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YANG Jin, YING Zechen, ZHANG Yun, ZHOU Huamin. Non-uniform Compensation Technology for Precision Injection Molding Based on High-precision Simulation[J]. Journal of Netshape Forming Engineering. 2025, 17(11): 1-12 https://doi.org/10.3969/j.issn.1674-6457.2025.11.001

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