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MuCell injection molding

Forming process where a gas is added to the molten polymer mass to create a porous detail.

Beskrivning
Illustration of MuCell injection molding

The process

Plastic pellets [1] are supplied via a hopper into a rotating screw [2] whose spiral shape moves the pellet forward through a heated chamber [3].The pellets are heated gradually blending into a homogeneous plastic melt. Then, a gas [4] through continued mechanical processing of the screw is fragmented into small bubbles.

The mixed mass is then forced into a mold [5] as the entire screw is pushed forward by an applied pressing force. The small gas bubbles grows larger during cooling and thus creates a porous interior while the surface is solid. The mold is opened and finally the part is removed by means of ejectors [6].

MuCell injection molding
Advantages and disadvantages
In comparison with alternative methods
Reduced costs
Quick casting process
Small casting machine
Ability to design both thin and thick walls
Improved dimensional accuracy
Reduced distortion
Less material consumption, lower density
Less predictable heterogeneous material structure
Not suitable for small series production
expensive process