This master thesis deals with design of injection moulding technology for plastic holder of carbon brushes made of polycarbonate labelled Lexan 945A. The injection is performed into injection mould with hot runner system. Initially there is general study related to plastics and injection moulding technology. Further the study continues with injection moulds with hot runners and ends with computer analysis of injection moulding process. The designed injection mould for production of plastic holders is three-plate, double cavity mould with four hot nozzles and one parting plane, where one of the plates serves for mounting of the hot runner system inside the mould. This work contains part of the drawing documentation and item list of the injection mould. The selected injection moulding machine is Arburg Allrounder 370 U labelled 700-290 according to EUROMAP.

Diploma thesis is focused on injection molding and welding technology of plastic materials. First, in theoretical part, are commonly described polymer materials, following by description of welding, and multi-injection molding. There are closely described different methods for chosen part. Practical part is about comparison of method according differ criteria and application suitability. At the end of the thesis there is economic estimation of methods.

My thesis presents the process of electromagnet production, including how the process is organised. My goal is to improve these techniques by refining them. To obtain the required data, the company's records were extracted and measurements were taken directly from the manufacturing process. Through examination of the data, any processes which created financial or temporal deficits were identified. Conclusions were then offered to solve these problem areas. These mainly involve alterations to the machinery settings, the delivery of materials and the management of production.

The project elaborated in scope of engineering studies branch 2307. The project is submitting design of production technology of car emblem. Different manufacturing technologies have been compared based on study of technical literature. Most suitable technologies have been chosen such as pressure die casting, especially aluminum alloys and plastic injection molding. Plastic part is metal plated afterwards in order to get desired metal look. Part of this project is injection molding tool design inclusive technical, technological and economic analysis.

This thesis contains of theoretical part which deals with injection molding, properties of some polymer materials are included also. Design of plastic injection mold for cover of electronic device is presented in practical part. Manufacturing parameters and injection machine selection are specified with mold structure consideration. Production costs and the final price of the plastic part are calculated in economical evaluation.

Diploma thesis which is developed for the master’s degree program (M2I – K Mechanical engineering) presents a proposal solution for production technology plastic car headlins parts from polymer material PBT GF30. Literature review summarizes the findings of thermoplastic injection technology and the structural design possibility of injection molds. The paper examined two variants of the running system, which are suitable for production of injection molding components. Finaly, after technical - economic assessment, we came to the conclusion that the better option is to use the hot runner system. In the practical part is the specified product modeled by the help of 3D software and the injection mold was designed. The design was implemented by CATIA V5 R20. For the design and manufacture of injection mold were used normality from MEUSBURGER. For the chosen alternative technology of production were made calculations and was selected injection molding machine Electron 75 – 300 from FERROMATIC.

This master thesis deals with design of injection molding technology for plastic lamp shade made of polycarbonate labelled Lexan 925. The injection is performed into injection mold with hot runner system. Initially there is a general study related to plastic materials and injection molding technology. Further the study continues with technological solution of production of the lamp shade. The designed injection mold is two-plate, double cavity mold with two hot nozzles and is equipped with a thread-unscrewing machine. This thesis contains part of the documentation and item list of the injection mold, along with technical-economical evaluation of the developed solution.

Nowadays, the filling and solidification of macro-scale injection mouldings can be predicted using commercial CAE software. For micro-injection moulding, the conventional tools do not work for all process conditions. The reasons might be the lack of high quality database used in the simulation and the improperly specified boundary conditions which do not reflect the real state in the cavity. Special aspects like surface tension or "size dependent" viscosity might also be responsible for the inaccuracy of the simulations. In this paper, those aspects related to the boundary conditions were taken into consideration, especially the thermal contact behaviour and the melt compression in the barrel which affects not only the temperature of the melt due to the compression heating, but also reduces the actual volume rate in the cavity. It can be shown that the heat transfer coefficient between the melt and the mould wall has a significant influence on the simulation results. In combination with precise material data and considering the reduction of the volume rate due to the melt compression in the barrel, the heat transfer coefficient may be quantified by means of reverse engineering. In general, it decreases when either the cavity thickness or the injection speed increases. It is believed that a pressure dependent model for the heat transfer coefficient would be more suitable to describe the thermal contact behaviour in micro injection moulding. The melt compression in the barrel affects definitely the filling behaviour and subsequently the heat transfer in the cavity as well, which is especially true for micro parts of high aspect ratio.

Liquid composite molding (LCM) is growing in importance alternative to traditional prepreg-autoclave methods for manufacture aerospace composites. The most significant roadblock to industry's implementation of LCM is the optimization of resin flow to ensure high quality parts. This study developed process optimization tools to foster the adaptation of LCM. The following dissertation characterized the permeability of reinforcement fabrics under various processing conditions, and investigated in-situ bubble flow with carbon fiber. The purpose of this research is to extend the understanding of LCM and push forward the state of the art via sub-studies captured in five chapters, or manuscripts. Research from these manuscripts is as follows. Chapter 3 sets the groundwork for LCM optimization by extending the current theory for assessing 3D permeability of reinforcement fabrics using an ellipsoidal point infusion experiment. The aim was to improve 3D permeability measurement accuracy for LCM processing models. This work is the first to compare solutions in the context of 75 experiments. Chapters 4 and 5 extend permeability analysis to curved and sheared geometries, typical to real-world aerostructures. Chapter 4 demonstrates a method for measurement of curvature effects on permeability with vacuum infusion. A correlation was shown between curvature (as evaluated over four radii) and effective permeability. Chapter 5 researches the shearing of reinforcement fabric (e.g. when reinforcements are draped over double curvature). The study shows that permeability actually increases for mid-range shear angles beyond the shear-locking angle, and develops a technique for obtaining the 3D permeability of sheared fabric.Chapter 6 investigates carbon fiber voids in situ. LCM optimization requires improved void monitoring for carbon fiber. It is challenging to monitor void flow in situ with carbon fiber reinforcements because of fiber opacity. The research builds upon a new automated fluorescent imaging method to monitor void flow in-situ. Results include high-resolution and high-contrast images and 230 data points for infusion velocity vs. void content data.Chapter 7 contributes to the growing interest in LCM processes for aerospace applications by providing a short cost summary of typical processes for manufacturing aerospace composite parts. Data shows that LCM is a financially wise alternative to automated fiber placement (prepreg-autoclave) manufacturing when a void content of 2-2.5% is acceptable. Work on LCM processes optimization indicates that these percentages will reduce in coming years.

Resin transfer molding (RTM) is an infusion-based closed-mold manufacturing process where resin is injected into a preform of dry reinforcement to create a net shape part. Often, when a preform is draped over a mold with complex geometry, such as the double curvature of a dome, a reorientation of the fibers takes place in the form of in-plane shear. This deformation of the reinforcement structure has the potential to adversely affect the resin flow and the filling of the mold during RTM if the manufacturer fails to properly account for the shear effects. Various process simulation tools are being developed and used to simulate infusions in a virtual environment and assist manufacturers in optimizing tooling features and process parameters before needing to invest in tooling or prototypes. Such simulation requires material characterization of the resin viscosity and reinforcement permeability. The latter is a function of the reinforcement architecture and is highly sensitive to perturbations such as shear. Permeability measurement is well represented in the literature, but for ideal fabric arrangements without the deformations caused by complex mold geometries typical to industrial parts. The purpose of this study is to develop the first method for measuring the three-dimensional (3D) permeability tensor of a sheared fiber reinforcement in a single test and empirical models to show the effect shear has on permeability. The method and models are intended to enhance the accuracy of infusion simulation and further advance the development of liquid composite molding processes. Building off the work of previous researchers who have used trellis tools to induce uniform shear on fabric samples and 3D point-infusion tools for radial flow tests, these two methods were combined to measure the sheared permeability of a carbon fiber non-crimp fabric (NCF) in the x, y, and z directions. To mitigate the amount of spring-back that occurs when transferring the sheared preform from the trellis tool to the permeability tool, a method of incorporating an adhesive binder into the preform is presented. Lastly, the permeability data obtained from testing samples sheared at 0, 10, 20, 30, and 40 degrees is documented. Mathematical models are provided based on the data gathered in this work that show the permeability of a NCF in the x, y, and z directions as a function of shear angle. The resulting models indicate an inverse correlation between permeability and shear due to the reorientation of the fibers and closure of preferential flow channels in the preform. These models can be used to predict the permeability for shear angles less than 40 degrees. To validate these results, theoretical shear permeability models are included for comparison. Recommendations for future studies involving the measurement of 3D sheared permeability are discussed.