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Zhang H, Liu H, Zhang N. A Review of Microinjection Moulding of Polymeric Micro Devices. MICROMACHINES 2022; 13:1530. [PMID: 36144153 PMCID: PMC9504769 DOI: 10.3390/mi13091530] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 08/12/2022] [Revised: 09/06/2022] [Accepted: 09/13/2022] [Indexed: 06/16/2023]
Abstract
Polymeric micro devices are gaining huge market potential in broad areas of medical devices, diagnostic devices, drug delivery, and optical applications. Current research is focusing on developing functional polymeric micro devices on a mass-production scale. Microinjection moulding is a promising technique suitable for fabricating polymeric micro devices. This review aims to summarise the primary achievements that have been achieved in various aspects of microinjection moulding of polymer micro devices, consisting of micro parts and micro surface structures. The relationships of the machine, process, rheology, tooling, micro/nanoscale replication, morphology, properties, and typical applications are reviewed in detail. Finally, a conclusion and challenges are highlighted.
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Affiliation(s)
- Honggang Zhang
- Faculty of Materials and Manufacturing, Beijing University of Technology, Beijing 100124, China
| | - Haibin Liu
- Faculty of Materials and Manufacturing, Beijing University of Technology, Beijing 100124, China
| | - Nan Zhang
- Centre of Micro/Nano Manufacturing Technology (MNMT-Dublin), School of Mechanical & Materials Engineering, University College Dublin, Belfield, D04 V1W8 Dublin, Ireland
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2
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Ben Ayad A, El Hakimi A, El Otmani R, El Magri A, Louanate A, Touache A, Boutaous M, Vaudreuil S. Microinjection molding of polyoxymethylene stepped‐parts: Morphology, crystallinity, shrinkage, and thermal characterization. J Appl Polym Sci 2022. [DOI: 10.1002/app.52930] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/22/2023]
Affiliation(s)
- Anass Ben Ayad
- Mechanical Engineering Laboratory Sidi Mohamed Ben Abdellah University Fez Morocco
| | - Abdelhadi El Hakimi
- Mechanical Engineering Laboratory Sidi Mohamed Ben Abdellah University Fez Morocco
| | - Rabie El Otmani
- Science Engineer Laboratory for Energy (LabSIPE) Chouaib Doukkali University El Jadida Morocco
| | - Anouar El Magri
- Euromed Polytechnic School Euromed Research Center, Euromed University of Fes Fès‐Morocco
| | | | - Abdelhamid Touache
- Mechanical Engineering Laboratory Sidi Mohamed Ben Abdellah University Fez Morocco
| | - M'hamed Boutaous
- CETHIL UMR 5008, CNRS, National Institute of Applied Sciences Lyon University Villeurbanne France
| | - Sébastien Vaudreuil
- Euromed Polytechnic School Euromed Research Center, Euromed University of Fes Fès‐Morocco
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3
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Surace R, Pagano C, Bellantone V, Gatti S, Castellani L, Vighi M, Stoclet G, Sechi S, Fassi I, Baldi F. Injection vs micro-injection molding of nano-particle filled polyamide 6: Moldability and structuring. POLYMER 2021. [DOI: 10.1016/j.polymer.2021.124035] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/15/2022]
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4
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Liao T, Zhao X, Yang X, Coates P, Whiteside B, Jiang Z, Men Y. Structural evolution of flow-oriented high density polyethylene upon heating: In situ SAXS and WAXD studies. POLYMER 2019. [DOI: 10.1016/j.polymer.2019.121698] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/15/2022]
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5
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Shi S, Zhao K, Wang L, Lu B, Zheng G. Crystallization Behavior and Mechanical Properties of Microinjection Molded High Density Polyethylene Parts. J MACROMOL SCI B 2018. [DOI: 10.1080/00222348.2018.1449930] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/17/2022]
Affiliation(s)
- Suyu Shi
- College of Materials and Chemical Engineering, Henan Institute of Engineering, Zhengzhou, 450007, P.R. China
| | - Kang Zhao
- College of Materials Science and Engineering, National Engineering Research Center for Advanced Polymer Processing Technology, Zhengzhou University, Zhengzhou, 450002, P.R. China
| | - Lina Wang
- College of Materials and Chemical Engineering, Henan Institute of Engineering, Zhengzhou, 450007, P.R. China
| | - Bo Lu
- College of Materials Science and Engineering, National Engineering Research Center for Advanced Polymer Processing Technology, Zhengzhou University, Zhengzhou, 450002, P.R. China
| | - Guoqiang Zheng
- College of Materials Science and Engineering, National Engineering Research Center for Advanced Polymer Processing Technology, Zhengzhou University, Zhengzhou, 450002, P.R. China
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6
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Wang L, Zhang Y, Jiang L, Yang X, Zhou Y, Wang X, Li Q, Shen C, Turng LS. Effect of injection speed on the mechanical properties of isotactic polypropylene micro injection molded parts based on a nanoindentation test. J Appl Polym Sci 2018. [DOI: 10.1002/app.47329] [Citation(s) in RCA: 11] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/30/2023]
Affiliation(s)
- Lixia Wang
- School of Mechanics and Engineering Science, Zhengzhou University; Zhengzhou Henan, 450001 People's Republic of China
- National Centre for International Joint Research of Micro-Nano Moulding Technology; Zhengzhou University; Zhengzhou Henan, 450001 People's Republic of China
| | - Yang Zhang
- School of Mechanics and Engineering Science, Zhengzhou University; Zhengzhou Henan, 450001 People's Republic of China
| | - Lin Jiang
- State Key Laboratory of Materials Processing and Die and Mould Technology; Huazhong University of Science and Technology; Wuhan 430074 People's Republic of China
- Wisconsin Institute for Discovery; University of Wisconsin-Madison; Madison Wisconsin 53706 United States of America
| | - Xuecheng Yang
- School of Mechanics and Engineering Science, Zhengzhou University; Zhengzhou Henan, 450001 People's Republic of China
| | - Yiping Zhou
- School of Mechanics and Engineering Science, Zhengzhou University; Zhengzhou Henan, 450001 People's Republic of China
| | - Xiaoyu Wang
- School of Mechanics and Engineering Science, Zhengzhou University; Zhengzhou Henan, 450001 People's Republic of China
| | - Qian Li
- School of Mechanics and Engineering Science, Zhengzhou University; Zhengzhou Henan, 450001 People's Republic of China
- National Centre for International Joint Research of Micro-Nano Moulding Technology; Zhengzhou University; Zhengzhou Henan, 450001 People's Republic of China
| | - Changyu Shen
- National Centre for International Joint Research of Micro-Nano Moulding Technology; Zhengzhou University; Zhengzhou Henan, 450001 People's Republic of China
| | - Lih-Sheng Turng
- Wisconsin Institute for Discovery; University of Wisconsin-Madison; Madison Wisconsin 53706 United States of America
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7
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Kaneda R, Takahashi T, Takiguchi M, Hijikata M, Ito H. Optical properties of high-density polyethylene in injection press molding for IR system lenses. POLYM ENG SCI 2018. [DOI: 10.1002/pen.24592] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/11/2022]
Affiliation(s)
- Ryo Kaneda
- Yamagata Research Institute of Technology; 2-2-1 Matsuei, Yamagata Yamagata 990-2473 Japan
| | - Toshihiro Takahashi
- Yamagata Research Institute of Technology; 2-2-1 Matsuei, Yamagata Yamagata 990-2473 Japan
| | - Masayasu Takiguchi
- Yamagata Factory, Chino Corporation; 1515 Midarekawa, Tendo Yamagata 994-0002 Japan
| | - Motoharu Hijikata
- Yamagata Factory, Chino Corporation; 1515 Midarekawa, Tendo Yamagata 994-0002 Japan
| | - Hiroshi Ito
- Graduate School of Organic Materials Science, Yamagata University; 4-3-16 Jonan, Yonezawa Yamagata 992-8510 Japan
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Thin-wall injection molding of high-density polyethylene for infrared radiation system lenses. JOURNAL OF POLYMER ENGINEERING 2018. [DOI: 10.1515/polyeng-2017-0077] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/15/2022]
Abstract
Abstract
High-density polyethylene (HDPE) lenses are used for infrared radiation (IR) systems, such as radiation thermometers to transmit the IR of the 10 μm region. High IR transmittance and low visible ray (VR) transmittance are necessary for IR system lenses. This experimental investigation of thin-wall injection molding was conducted using 0.5 mm cavity thickness with a disk shape, finished to a mirror-like surface. As factors affecting transmittance, we evaluated the thickness, surface roughness, crystallinity, internal structure, and molecular chain orientation of molded parts, which were produced using four HDPE melt flow rates (MFRs). The changed molding conditions were mold temperature and holding pressure. Results showed that the thin-molded parts had higher IR transmittance. The thin-molded part was obtained with the smallest MFR of 5. Furthermore, the VR transmittance decreased when the molecular chain orientation in the molded parts was small and the crystallinity was high. The small orientation and high crystallinity were obtained simultaneously with the largest MFR of 42. Therefore, it was impossible to obtain high IR transmittance and low VR transmittance simultaneously by a change of MFR. This study confirmed that surface roughness and crystallinity do not affect transmittance.
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Zhou S, Hrymak AN, Kamal MR. Microinjection molding of multiwalled carbon nanotubes (CNT)-filled polycarbonate nanocomposites and comparison with electrical and morphological properties of various other CNT-filled thermoplastic micromoldings. POLYM ADVAN TECHNOL 2018. [DOI: 10.1002/pat.4282] [Citation(s) in RCA: 17] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/10/2022]
Affiliation(s)
- Shengtai Zhou
- Department of Chemical and Biochemical Engineering; The University of Western Ontario; London Ontario N6A 5B9 Canada
| | - Andrew N. Hrymak
- Department of Chemical and Biochemical Engineering; The University of Western Ontario; London Ontario N6A 5B9 Canada
| | - Musa R. Kamal
- Department of Chemical Engineering; McGill University; Montreal Québec H3A 0C5 Canada
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Li M, Yang Q, Kong M, Huang Y, Liao X, Niu Y, Zhao Z. Role of dicumyl peroxide on the morphology and mechanical performance of polypropylene random copolymer in microinjection molding. POLYM ADVAN TECHNOL 2017. [DOI: 10.1002/pat.4099] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/08/2022]
Affiliation(s)
- Mengjue Li
- College of Polymer Science and Engineering; Sichuan University; Chengdu 610065 China
- School of Applied and Chemical Engineering; Xichang College; Xichang 615053 China
| | - Qi Yang
- College of Polymer Science and Engineering; Sichuan University; Chengdu 610065 China
- State Key Laboratory of Polymer Materials Engineering of China; Sichuan University; Chengdu 610065 China
| | - Miqiu Kong
- College of Aeronautics and Astronautics; Sichuan University; Chengdu 610065 China
| | - Yajiang Huang
- College of Polymer Science and Engineering; Sichuan University; Chengdu 610065 China
- State Key Laboratory of Polymer Materials Engineering of China; Sichuan University; Chengdu 610065 China
| | - Xia Liao
- College of Polymer Science and Engineering; Sichuan University; Chengdu 610065 China
| | - Yanhua Niu
- College of Polymer Science and Engineering; Sichuan University; Chengdu 610065 China
| | - Zhongguo Zhao
- College of Polymer Science and Engineering; Sichuan University; Chengdu 610065 China
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Kaneda R, Takahashi T, Takiguchi M, Hijikata M, Ito H. Optical Properties of HDPE in Injection Molding and Injection Press Molding for IR System Lenses Part II: Mold Temperature and Surface Roughness Effects on Injection Molding. INT POLYM PROC 2017. [DOI: 10.3139/217.3333] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/20/2022]
Abstract
Abstract
An experimental investigation of injection molding was conducted to assess the high infrared radiation (IR) transmittance with an opaque state (low visibility ray (VR) transmittance) necessary for IR system lenses as a target high-density polyethylene (HDPE) IR transmission material. In our earlier investigation, experimental investigations of injection molding and injection press molding were conducted using the mold cavity of a disk-shaped finished mirror-like surface. For high mold temperature and long cooling time, the increased core-layer thickness improved the IR transmittance. Simultaneously, the VR transmittance decreased because the crystallinity became higher. Furthermore, when injection press molding was done, the VR transmittance decreased because the crystallinity increased. Using a 0.5-mm-thick mold cavity with disk shapes having different surface roughness, an injection molding experiment was conducted for this study while changing only the mold temperature of 20 to 80°C. Results show that when the mold surface roughness became high, the surface roughness of molded parts became high, too. Thereby the IR and VR transmittance were decreased. However, when the mold temperature was high, the influences of the so-called skin-core structure and crystallinity were stronger than the influence of the surface roughness of molded parts. The IR transmittance increased because of the decrease of the skin layer. Furthermore, the VR transmittance decreased because of a simultaneous rise of the crystallinity. The minimum value of obtained VR transmittance was 9.3% at mold temperature of 80°C using a mold of the highest surface roughness. This molded part reached an opaque state. Furthermore, a higher IR transmittance of 64.9% was obtained. When injection molding was conducted using a mold of a mirror-like surface with the same conditions as those in this investigation in our earlier investigation, the obtained IR and VR transmittances were 65.4% and 0.6%, respectively. Consequently, when the mold temperature was high, a few differences were found with transmittance of the molded parts using the mold of the mirror-like surface. Results showed that no difficulty arises when a mold having higher surface roughness is used at a higher mold temperature.
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Affiliation(s)
- R. Kaneda
- Department of Precision Machining and Metal Engineering , Yamagata Research Institute of Technology, Yamagata , Japan
- Graduate School of Organic Materials Science , Yamagata University, Yamagata , Japan
| | - T. Takahashi
- Department of Precision Machining and Metal Engineering , Yamagata Research Institute of Technology, Yamagata , Japan
| | - M. Takiguchi
- Department of Development , Chino Corporation Yamagata Factory, Yamagata , Japan
| | - M. Hijikata
- Department of Development , Chino Corporation Yamagata Factory, Yamagata , Japan
| | - H. Ito
- Graduate School of Organic Materials Science , Yamagata University, Yamagata , Japan
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Kaneda R, Takahashi T, Takiguchi M, Hijikata M, Ito H. Optical Properties of HDPE in Injection Molding and Injection Press Molding for IR System Lenses. INT POLYM PROC 2016. [DOI: 10.3139/217.3261] [Citation(s) in RCA: 7] [Impact Index Per Article: 0.9] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/20/2022]
Abstract
Abstract
To obtain the “high infrared radiation (IR) transmittance and low visible ray (VR) transmittance” necessary for a high-performance IR lens, cavity thickness and molding conditions were investigated experimentally for disk-shaped high-density polyethylene (HDPE). When injection molding and injection press molding were done using different cavity thicknesses, results showed that the molded part using the thinner cavity thickness maintained a semitransparent state. Simultaneously, they showed that higher IR transmittance was obtained. For high mold temperature and long cooling time, the increased core-layer thickness improved the IR transmittance. The VR transmittance decreased because crystallinity became higher. Furthermore, when injection press molding was conducted, the VR transmittance decreased because crystallinity became higher. IR transmittance and VR transmittance were obtained respectively as 65.4% and 6.4% when injection press molding was conducted at higher mold temperatures with longer cooling times.
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Affiliation(s)
- R. Kaneda
- Department of Precision Machining and Metal Engineering , Yamagata Research Institute of Technology, Yamagata , Japan
- Graduate School of Science and Engineering , Yamagata University, Yamagata , Japan
| | - T. Takahashi
- Department of Precision Machining and Metal Engineering , Yamagata Research Institute of Technology, Yamagata , Japan
| | - M. Takiguchi
- Department of Development , Chino Corporation, Yamagata Factory, Yamagata , Japan
| | - M. Hijikata
- Department of Development , Chino Corporation, Yamagata Factory, Yamagata , Japan
| | - H. Ito
- Graduate School of Science and Engineering , Yamagata University, Yamagata , Japan
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Zhao Z, Yang Q, Xiang Z, Kong M, Tang D, Huang Y, Liao X, Niu Y. Effect ofin situpoly(ethylene terephthalate) (PET) microfibrils on the morphological structure and crystallization behavior of isotactic polypropylene (iPP) under an intensive shear rate. POLYM ADVAN TECHNOL 2015. [DOI: 10.1002/pat.3565] [Citation(s) in RCA: 13] [Impact Index Per Article: 1.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/12/2022]
Affiliation(s)
- Zhongguo Zhao
- College of Polymer Science and Engineering, the State Key Laboratory for Polymer Materials Engineering; Sichuan University; Chengdu 610065 China
| | - Qi Yang
- College of Polymer Science and Engineering, the State Key Laboratory for Polymer Materials Engineering; Sichuan University; Chengdu 610065 China
| | - Zhang Xiang
- College of Polymer Science and Engineering, the State Key Laboratory for Polymer Materials Engineering; Sichuan University; Chengdu 610065 China
| | - Miqiu Kong
- School of Aeronautics and Astronautics; Sichuan University; Chengdu 610065 China
| | - Dahang Tang
- College of Polymer Science and Engineering, the State Key Laboratory for Polymer Materials Engineering; Sichuan University; Chengdu 610065 China
| | - Yajiang Huang
- College of Polymer Science and Engineering, the State Key Laboratory for Polymer Materials Engineering; Sichuan University; Chengdu 610065 China
| | - Xia Liao
- College of Polymer Science and Engineering, the State Key Laboratory for Polymer Materials Engineering; Sichuan University; Chengdu 610065 China
| | - Yanhua Niu
- College of Polymer Science and Engineering, the State Key Laboratory for Polymer Materials Engineering; Sichuan University; Chengdu 610065 China
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Ding W, Chen Y, Liu Z, Yang S. In situ nano-fibrillation of microinjection molded poly(lactic acid)/poly(ε-caprolactone) blends and comparison with conventional injection molding. RSC Adv 2015. [DOI: 10.1039/c5ra15402b] [Citation(s) in RCA: 27] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/21/2022] Open
Abstract
During microinjection molding, there are highly oriented PCL nanofibrils in situ formed, while during conventional injection molding, there are oriented microfibrils in situ formed.
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Affiliation(s)
- Weiwei Ding
- State Key Laboratory of Polymer Materials Engineering
- Polymer Research Institute
- Sichuan University
- Chengdu 610065
- China
| | - Yinghong Chen
- State Key Laboratory of Polymer Materials Engineering
- Polymer Research Institute
- Sichuan University
- Chengdu 610065
- China
| | - Zhuo Liu
- State Key Laboratory of Polymer Materials Engineering
- Polymer Research Institute
- Sichuan University
- Chengdu 610065
- China
| | - Sen Yang
- State Key Laboratory of Polymer Materials Engineering
- Polymer Research Institute
- Sichuan University
- Chengdu 610065
- China
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Wang S, Wang Z, Zhao N, Jiang J, Li Q. A novel morphology development of micro-injection molded isotactic polypropylene. RSC Adv 2015. [DOI: 10.1039/c5ra04626b] [Citation(s) in RCA: 5] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/21/2022] Open
Abstract
The appearance of a stripe morphology in MIM-iPP was induced by the optical path difference of the polarized light on the polymer crystal.
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Affiliation(s)
- Shiwei Wang
- National Center For International Joint Research of Micro-Nano Molding Technology
- Zhengzhou University
- Zhengzhou
- China
| | - Zhenwei Wang
- National Center For International Joint Research of Micro-Nano Molding Technology
- Zhengzhou University
- Zhengzhou
- China
| | - Na Zhao
- National Center For International Joint Research of Micro-Nano Molding Technology
- Zhengzhou University
- Zhengzhou
- China
| | - Jing Jiang
- National Center For International Joint Research of Micro-Nano Molding Technology
- Zhengzhou University
- Zhengzhou
- China
| | - Qian Li
- National Center For International Joint Research of Micro-Nano Molding Technology
- Zhengzhou University
- Zhengzhou
- China
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Ferreira T, Lopes PE, Pontes AJ, Paiva MC. Microinjection molding of polyamide 6. POLYM ADVAN TECHNOL 2014. [DOI: 10.1002/pat.3322] [Citation(s) in RCA: 11] [Impact Index Per Article: 1.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/12/2022]
Affiliation(s)
- Tânia Ferreira
- Institute for Polymers and Composites/I3N; University of Minho; 4800-058 Guimarães Portugal
| | - Paulo E. Lopes
- Pole for Innovation in Polymer Engineering-PIEP; University of Minho; 4800-058 Guimarães Portugal
| | - António José Pontes
- Institute for Polymers and Composites/I3N; University of Minho; 4800-058 Guimarães Portugal
| | - Maria Conceição Paiva
- Institute for Polymers and Composites/I3N; University of Minho; 4800-058 Guimarães Portugal
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