{"id":14065,"date":"2026-10-06T12:04:14","date_gmt":"2026-10-06T10:04:14","guid":{"rendered":"https:\/\/ikv-aachen.de\/rp\/development-of-an-injection-strategy-for-cascade-injection-moulding-to-achieve-a-uniform-flow-front-velocity\/"},"modified":"2026-10-07T12:42:15","modified_gmt":"2026-10-07T10:42:15","slug":"development-of-an-injection-strategy-for-cascade-injection-moulding-to-achieve-a-uniform-flow-front-velocity","status":"publish","type":"cpt_ikv_rp","link":"https:\/\/ikv-aachen.de\/en\/rp\/development-of-an-injection-strategy-for-cascade-injection-moulding-to-achieve-a-uniform-flow-front-velocity\/","title":{"rendered":"Development of an injection strategy for cascade injection moulding to achieve a uniform flow front velocity"},"content":{"rendered":"<style type=\"text\/css\">\n    #single-header-block_b857199f47d11a9fb7827b0b1ad88660 .swiperThumbsNavi .swiper-slide {\n        opacity: 0.4;\n    }\n\n    #single-header-block_b857199f47d11a9fb7827b0b1ad88660 .swiperThumbsNavi .swiper-slide-thumb-active {\n        opacity: 1;\n    }\n<\/style>\n    <section id=\"single-header-block_b857199f47d11a9fb7827b0b1ad88660\" class=\"block-single-header theGridWrapper \">\n        <div class=\"theGrid12\">\n            <div class=\" col-start-2 col-span-10 md:col-start-3  md:col-span-8\">\n                <h2 class=\"font-serif font-semibold text-blue text-sm w-4\/5\">\n                    Methodology for the Automated Design and Validation of a Uniform Flow Front Path                <\/h2>\n                                    <div class=\"mt-base text-blue text-sm font border-l-8  border-blue pl-base my-12 leading-normal \">\n                        Cascade injection moulding is the method of choice for parts with high surface quality requirements and large flow path\/wall thickness ratios. Due to the complex interrelationships, particularly between the injection flow rate profile set on the machine and the interaction of the individual hot runner pin controls, the process setup is very complex and involves a large number of experimental tests.                    <\/div>\n                                            <\/div>\n        <\/div>\n    <\/section>\n\n\n<figure class=\" relative flex flex-col gap-2xs mb-xs md:mb-l xl:mb-xl\"><img decoding=\"async\"  class=\" w-full  \"  src=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2026\/10\/HO4776_102-1.jpg\" srcset=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2026\/10\/HO4776_102-1-748x499.jpg 748w, https:\/\/ikv-aachen.de\/wp-content\/uploads\/2026\/10\/HO4776_102-1-1536x1024.jpg 1536w, https:\/\/ikv-aachen.de\/wp-content\/uploads\/2026\/10\/HO4776_102-1-768x512.jpg 768w\" sizes=\"auto, (max-width: 1536px) 100vw, 1536px\" width=\"1536\" height=\"1024\" alt=\"HO4776_102-1\" loading=\"lazy\" \/><span class=\" text-copyright order-3 justify-end text-right w-full  w-full \">&copy; IKV<\/span><figcaption class=\" w-full  text-figcaption justify-end text-right \">Fig. 1: Schematic representation of cascade injection moulding<\/figcaption><\/figure>\n\n\n<p class=\"wp-block-paragraph\">The DFG funded OptiKas research project aims to develop a methodology for deriving an injection strategy for cascade injection moulding that delivers high-quality parts regardless of the machine operator\u2019s experience and without the need for extensive testing. To achieve a consistently high surface quality along the entire flow path, a constant flow front velocity is to be maintained within the cavity.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">As a first step, automated iterative simulations, that take the cascade into account, will be used to determine the gate-specific target injection volume flow profiles in order to achieve a constant target flow front velocity within the cavity. On this basis, a process model is used to calculate the individual valve gate pin stroke profiles and the machine side injection flow rate profile. The process model takes the interaction between the flow rates of the individual hot runner gates into account. The injection strategy developed is validated and optimised through experimental trials for different geometries, material types and process settings. Furthermore, the effect of the injection strategy on surface quality, such as gloss, roughness and molecular orientation in the surface layer, is investigated.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">To conclude the project, the robustness of the process against process fluctuations will be analysed in order to derive key performance indicators for monitoring the filling phase of cascade injection moulding. Furthermore, the potential effect of an adaptive control strategy will be assessed on the basis of the experiments.<\/p>\n\n\n\n<details class=\"wp-block-details is-layout-flow wp-block-details-is-layout-flow\"><summary>Project data and Funding<\/summary>\n<p class=\"wp-block-paragraph\">We would like to thank the DFG for funding this project (grant number: HO 4776\/102-1) and our project partners for their collaboration.<\/p>\n\n\n<section id=\"logo-bar-block_19bd4642ac8cac955fe4ed1647836362\" class=\"block-logo-bar py-2xl  clear-both\">\n    <div class=\"theGridWrapper overflow-hidden  \">\n        <div class=\"grid grid-cols-[repeat(auto-fill,minmax(140px,1fr))] gap-base\">\n                            <figure class=\" relative h-full  \"><img decoding=\"async\" fetchpriority=\"low\"  class=\" object-contain w-full h-full mb-base  \"  src=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2024\/12\/Logo-DFG.png\" srcset=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2024\/12\/Logo-DFG-748x591.png 748w\" sizes=\"auto, (max-width: 748px) 100vw, 748px\" width=\"748\" height=\"591\" alt=\"Logo-DFG\" loading=\"lazy\" \/><\/figure>                                <\/div>\n    <\/div>\n<\/section>\n<\/details>\n","protected":false},"excerpt":{"rendered":"<p>Cascade injection moulding is the method of choice for parts with high surface quality requirements and large flow path\/wall thickness ratios. Due to the complex interrelationships, particularly between the injection flow rate profile set on the machine and the interaction of the individual hot runner pin controls, the process setup is very complex and involves a large number of experimental tests.<\/p>\n","protected":false},"featured_media":14031,"parent":0,"template":"","tags":[],"research_fields":[813],"class_list":["post-14065","cpt_ikv_rp","type-cpt_ikv_rp","status-publish","has-post-thumbnail","hentry","research_fields-injection-moulding"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.5 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Development of an injection strategy for cascade injection moulding to achieve a uniform flow front velocity | IKV-Aachen<\/title>\n<meta name=\"description\" content=\"Cascade injection moulding is the method of choice for parts with high surface quality requirements and large flow path\/wall thickness ratios. Due to the complex interrelationships, particularly between the injection flow rate profile set on the machine and the interaction of the individual hot runner pin controls, the process setup is very complex and involves a large number of experimental tests.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/ikv-aachen.de\/en\/rp\/development-of-an-injection-strategy-for-cascade-injection-moulding-to-achieve-a-uniform-flow-front-velocity\/\" \/>\n<meta property=\"og:locale\" content=\"en_GB\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Development of an injection strategy for cascade injection moulding to achieve a uniform flow front velocity | IKV-Aachen\" \/>\n<meta property=\"og:description\" content=\"Cascade injection moulding is the method of choice for parts with high surface quality requirements and large flow path\/wall thickness ratios. 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