Substitution of the filter material
Can a filter fabric be replaced by an injection-moulded plastic filter structure?
In order to reduce material costs, it should be examined whether a woven plastic fabric can be replaced by an injection-moulded filter structure. The challenges for implementation are diverse. A structured approach helps to implement the project.
- Assessment of the feasibility
- Assessment of the process stability
- Evaluation of material
- Pre-series tool concept
To make the first step, a 3D model of the filter was built and a tool concept was created to do a filling simulation.
Excerpt from the filling simulation
Assessment feasibility injection moulding tool
The feasibility for the production of an injection moulding tool was examined.
Assessment of injection moulding process
The injection moulding process was evaluated using a filling simulation.
Evaluation of material
A suitable plastic material with the appropriate flow properties was evaluated.
2-cavity pre-series tool
For the proof of concept, it was decided to design and build a 2-cavity pre-production tool.
The function of the new tool concept could be tested with the 2-cavity pre-series tool.
Optimisation of the tool concept
Based on the findings from the functional sampling of the 2-cavity pre-series tool, a tool concept for series production could be created.
Series production concept
On this basis, a concept and offer for series production could be submitted to the customer.
Using a filling simulation, it was possible to determine how the injected filter structure fills in the injection moulding tool.
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