Impact of Adaptive Process Control on Mechanical Properties of Plastic Parts and Process Robustness

This work aimed to assess the influence of the iQ Weight Control System on the weight, dimensional stability, and mechanical properties of injection-molded samples. The properties of products made from glass fiber-reinforced polyamide and 50% regrind from post-production waste were evaluated. The mechanical properties, such as impact strength and tensile strength, were measured to determine the material’s performance. Additionally, a spiral flow test was conducted to verify the process robustness and repeatability when producing with either virgin material or a blend of virgin and regrind material. The spiral flow test, which involves injecting the polymer melt into a spiral mold, provides insights into the processability and flow characteristics of the polymer under high shear rates. This test is crucial for assessing the consistency of the injection molding process and ensuring that the material maintains its properties across different production batches. Results demonstrated that, despite the viscosity reduction associated with regrind, the system successfully maintained a consistent shot weight, thereby stabilizing the amount of material injected into the mold cavity. The iQ Weight Control System activation led to an increase in impact strength from 9.50 kJ/m2 to 10.78 kJ/m2 for virgin samples and from 9.26 kJ/m2 to 9.73 kJ/m for a 50/50 virgin/regrind blend.