Topology optimization of a nonlinear ferrite core for induction heating in injection molding

Purpose Recent progress in additive manufacturing methods alleviated manufacturing constraints on devices. Topology optimization (TO) methods can leverage these reduced limitations and this paper aims to study the use of these algorithms in induction heating for injection molding. Design/methodology/approach In this paper, TO is used to reduce the volume of ferrite in an injection molding tool while aiming at maximizing the performance of the device. Characteristics of the proposed solution such as efficiency and power density are compared to the ones of the original device. Findings The study shows that it is possible to reduce significantly the amount of ferrite used without impacting the efficiency. The thermal performances of the proposed solution present also slight improvements compared to the original solution. Originality/value Optimization algorithms are important for understanding how to design efficient electrical devices. In this paper, the application of TO for injection molding applications presents a new perspective in designing such components.