Title: Optimising aesthetic automotive component manufacturing: comparative analysis of injection pressure in injection compression moulding vs. injection moulding

Authors: Yousef Amer; Praveen Kelath; Ashraf Zaghwan

Addresses: Faculty of Science, Technology, Engineering and Maths, University of South Australia, Mawson Lakes Boulevard, Mawson Lakes, SA 5095, Adelaide, South Australia, Australia ' SMR Automotive Australia Pty. Limited, 18 Sherriffs Road, Lonsdale, South Australia, SA 5160, Australia ' Faculty of Sciences, Engineering, and Technology, The University of Adelaide, North Terrace, South Australia, SA 5000, Adelaide, Australia

Abstract: This study investigates the injection pressure differences between injection moulding (IM) and injection compression moulding (ICM) processes for manufacturing aesthetic automotive interior components. Using Autodesk Moldflow® software, we conducted a simulation-based analysis of ICM injection pressure for various specimens with wall thicknesses ranging from 1 mm to 4 mm and flow lengths from 50 mm to 300 mm, using PC Lexan LS1 material. The results show that the pressure disparity between IM and ICM increases with thicker walls and shorter flow lengths, ranging from 30% to 51%. Correlation analysis indicates a strong positive relationship (0.999) between IM and ICM, which is supported by regression analysis. Physical trials validate the simulation outcomes. Future research should address parameters such as material selection and process constraints. The implementation of ICM could enhance manufacturing efficiency for aesthetic automotive components, offering cost reductions and new business opportunities.

Keywords: injection compression moulding; ICM; simulation; injection pressure; Moldflow®; Radome badges; automotive; injection moulding.

DOI: 10.1504/IJMTM.2025.145950

International Journal of Manufacturing Technology and Management, 2025 Vol.39 No.3/4/5, pp.452 - 482

Received: 07 Mar 2024
Accepted: 03 Jun 2024
Published online: 30 Apr 2025 *

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