Optimization of injection molding conditions for polyphthalamide-based thermoplastic lighting packages for smart farms using three-dimensional flow analysis and the Taguchi method

In this study, the injection molding process of a polyphthalamide (PPA)-based thermoplastic polymer package was optimized for application in high-temperature and high-humidity smart farm environments. A numerical three-dimensional flow analysis was conducted to predict the shrinkage behavior under varying packing pressure, mold temperature, injection pressure, melt temperature, and packing time. The predicted results were applied using an orthogonal array, and the Taguchi method was employed to determine the influence of each factor and identify the optimal conditions. As a result, melt temperature and packing time were found to have the most significant statistical impact on shrinkage. Under the optimized conditions (packing pressure of 140 MPa, mold temperature of 90 ℃, injection pressure of 140 MPa, melt temperature of 280 ℃, and packing time of 20 s), the minimum shrinkage value (signal-to-noise ratio = − 12.36 dB) was achieved. The theoretical and experimental shrinkage results obtained from the optimized processing conditions were in excellent agreement.