Multi-objective optimization of process parameters in (PC/TPU) dual-material injection molding

Abstract Focusing on a dual-material translucent window (PC/TPU), this study aims to reduce warping deformation and volume shrinkage, thereby improving its surface molding quality. Six key process parameters in dual-material injection molding were selected as influencing factors. Warping deformation and volume shrinkage were taken as quality indicators. A Taguchi experimental design with 50 groups was used for Moldflow simulation. Additionally, the Gorilla Troops Optimization (GTO) algorithm was applied to optimize the parameters of the Generalized Additive Model (GAM). A mathematical model was established to link injection molding process parameters with quality objectives. Subsequently, the established mathematical model was globally optimized using the Multi-objective Dragonfly Algorithm (MODA). This yielded the optimal combination of process parameters. Compared to pre-optimization results, the warping deformation of the first PC injection was reduced by 9.77 %. Volume shrinkage was reduced by 21.63 %. For the second TPU injection, warping deformation was reduced by 13.29 %. Volume shrinkage was reduced by 4.48 %. These results demonstrate the effectiveness and reliability of the optimization method.