Surrogate-Assisted Many-Objective Optimization of Injection Molding: Effects of Objective Selection and Sampling Density

In injection molding, advanced numerical modeling tools, such as Moldex3D, can significantly improve product development by optimizing part functionality, structural integrity, and material efficiency. However, the complex and nonlinear interdependencies between the several decision variables and objectives, considering the various operational phases, constitute a challenge to the inherent complexity of injection molding processes. This complexity often exceeds the capacity of conventional optimization methods, necessitating more sophisticated analytical approaches. Consequently, this research aims to evaluate the potential of integrating intelligent algorithms, specifically the selection of objectives using Principal Component Analysis and Mutual Information/Clustering, metamodels using Artificial Neural Networks, and optimization using Multi-Objective Evolutionary Algorithms, to manage and solve complex, real-world injection molding problems effectively. Using surrogate modeling to reduce computational costs, the study systematically investigates multiple methodological approaches, algorithmic configurations, and parameter-tuning strategies to enhance the robustness and reliability of predictive and optimization outcomes. The research results highlight the significant potential of data-mining methodologies, demonstrating their ability to capture and model complex relationships among variables accurately and to optimize conflicting objectives efficiently. In due course, the enhanced capabilities provided by these integrated data-mining techniques result in substantial improvements in mold design, process efficiency, product quality, and overall economic viability within the injection molding industry.