Real-Time Optimal Parameter Recommendation for Injection Molding Machines Using AI with Limited Dataset

This paper presents an efficient parameter optimization approach to the plastic injection molding process to achieve high productivity. In collaboration with a company specializing in plastic injection-mold-based production, real process data was collected and used in this research. The result is an integrated framework, combining a genetic algorithm (GA) with a CatBoost-based surrogate model for multi-objective optimization of the injection molding machine parameters. The aim of the optimization is to minimize the cycle time and cycle energy while maintaining the product quality. Ten process parameters were optimized, which are machine-specific. An evolutionary optimization using the NSGA-II algorithm is used to generate the recommended parameter set. The proposed GA-surrogate hybrid approach produces the optimal set of parameters that reduced the cycle time by 4.5%, for this specific product, while maintaining product quality. Cycle energy was evaluated on an hourly basis; its variation across candidate solutions was limited, but it was retained as an optimization objective to support energy-based process optimization. A total of 95% of the generated solutions satisfied industrial quality constraints, demonstrating the robustness of the proposed optimization framework. While classical Design of Experiment (DOE) approaches require sequential physical trials, the proposed GA-surrogate framework achieves convergence in computational iterations, which significantly reduces machine usage for optimization. This approach demonstrates a practical way to automate data-driven process optimization in an injection mold machine for an industrial application, and it can be extended to other manufacturing systems that require adaptive control parameters.