Optimization of Processing Parameters for Improved Complex Shape Accuracy in <scp>PFA</scp> Injection Overmolding

ABSTRACT Metal injection overmolding, which combines the advantageous properties of metals and polymers into a single component, is gaining attention in industrial manufacturing. Due to its unique structures and complex manufacturing processes, few studies have explored how process parameters influence shape accuracy. This study investigates the effect of four process factors on the complex shape of an injection overmolded impeller made of perfluoroalkoxy. The Taguchi method uses an L 9 orthogonal array to optimize these factors. The impeller shapes are measured using an infrared thermal camera, and shape deviations are calculated with the Matchshapes algorithm by comparing them to a standard contour image. The results demonstrate that mold temperature has the greatest impact on shape accuracy, followed by holding time. The largest deviations occur at the blade corners, where plastic thickness varies. Process optimization through a verification test reduces the dissimilarity value to 0.02573, representing a 44.95% improvement over the initial smallest value of 0.04674. These findings suggest that optimizing process parameters can effectively enhance the shape quality of injection overmolding parts, potentially improving their physical performance. Furthermore, this measurement method is both contactless and compatible, making it suitable for rapid detection of large quantities in manufacturing.