GOALI: Intelligent Melt Rotation for Enhanced Injection Molding of Polymer and Nanocomposite Products

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This Grant Opportunity for Academic Liaison with Industry (GOALI) research project will provide for the development of a manufacturing advancement known as intelligent melt rotation for the enhanced molding of polymer and nanocomposite products. A distinction of the project will be a focus on very important but often overlooked polymer melt flow dynamics that occur in molding runner systems. Runner based flow issues in conventional systems can lead to dramatic undesired in-tooling melt flow imbalances and significant product quality problems. As an extension of an existing multi-year research partnership, a collaborative team of researchers at Lehigh University and Beaumont Technologies, Inc. will address these problems by advancing melt rotation science as a means to manipulate and optimize flow dynamics through runner systems. The project will include phases focused on 1) how melt rotation affects the evolution of critical product quality variables; 2) dimensional, mechanical, and electrical product quality enhancements that can be realized through melt rotation; and 3) the effects of melt rotation on the migration, dispersion, and distribution of any fillers to be included in products. If successful, the benefits of this research will include the development of the fundamental experimental and analytical science base required to determine exactly how, when, and where to apply melt rotation principles to achieve selected manufacturing goals. This will enhance U.S. competitiveness on the industrial front. From a broader perspective the project will also target enhanced education and engineering workforce diversity. A new cross-state outreach program will be developed that will partner Lehigh graduate and undergraduate students, Penn State Erie undergraduate students, and K-12 students from both ends of Pennsylvania on industry- oriented product realization projects involving melt rotation. This will establish collaborative, team-oriented, and interdisciplinary scientific advancement as an enjoyable and productive norm in the minds of all involved.