Experimental Investigation of the Effects of Process Parameters on Product Geometry and Weight in the Injection Molding Process with PE100 Material

This study investigates the influence of key process parameters on the geometric and physical properties of parts produced by injection molding using high-density polyethylene (PE100). The parameters include packing pressure, melt temperature, and cooling time which are systematically varied based on MoldFlow simulations. Samples are analyzed using an ATOS Q 3D scanning system and a high-precision digital scale. Results show that increasing packing pressure improves flatness and dimensional accuracy. While higher melt temperature enhances surface flatness, it also increases cylindrical deformations. Cooling time positively affects flatness but may lead to deformation in the upper cylinder. Regarding product weight, packing pressure has the most significant effect, followed by melt temperature, whereas cooling time shows minimal impact. The experimental findings offer practical and reliable insights for optimizing injection molding processes involving dense materials like PE100, providing meaningful contributions to both design and production strategies.