Quality control plastics injection molding process optimization software
The tool is expressly designed to optimize the machinery parameters, including process stabilization, shortened cycle times, and production efficiencies, most critical to zero-defect medical, automotive, electrical component, optical, and LSR plastics injection molding operations. Traditional injection molding machinery optimization involves time-consuming, manual “trial-and-error” adjustments of relevant parameters until all quality targets are met. During this phase, user experience with similar parts, materials and injection molding machinery is critical. Online process optimization (i.e., during active production) is even more complex, as each parameter change can mean new machinery setting modifications, cycle time data recording and molded parts measurements. Due to post-production shrinkage or water absorption, parts can take several days to be ready for use, often first requiring time-consuming readjustment of machinery operating points, creating costly downtime.
STASA QC is based on a repeatable systematic design of experiments (DOE) method for determining best machinery setting operating points, as well as online processes. With user-selectable parameters, such as holding pressure levels, injection speed and others, the software recommends a number of experiments, allowing for a setter to change or enhance a selection as needed. The DOE methodology allows for machinery behavior simulation and visualization, preventing unnecessary experiments. All parts created from these experiments and their associated geometries are analyzed to determine best machinery settings. All mathematical calculations occur in the background, with a minimum number of tests required to run at various parameter settings. During a typical STASA QC simulated injection molding process, experiments are carried out on a PC, with parameters that can be changed interactively by the clicking and dragging of a mouse. The effects of these changes on each quality feature can be tracked on-screen, without doing so on the injection molding machine.
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