Injection moulding is a staple of industrial production, responsible for creating everything from phone cases to medical devices. It is especially preferred for producing plastic parts quickly and efficiently. But even an industry favourite process this mature is not immune to inefficiencies.

The process of injection moulding entails melting plastic material and injecting it into a mould cavity, where it cools and solidifies into the desired shape, often in just a matter of seconds. This often leads to one of its most overlooked issues – air entrapment, where pockets of trapped gas form during the injection of molten polymer into a mould. These air traps may seem minor, but they lead to significant defects like burn marks, incomplete filling, weak weld lines, and unsightly surface blemishes. They also force manufacturers to slow down cycle times or discard faulty parts, resulting in more material waste, higher energy use, and increased costs.

How Local Innovation Fuels Sustainable Manufacturing

The VacuUM project, led by the University of Malta under the supervision of Prof. Arif Rochman and funded by Xjenza Malta through the FUSION R&I Technology Development Programme, set out to tackle this long-standing issue. The team developed and tested a new Active Vacuum Venting (AVV) system – a smart, modular unit that could be fitted onto existing injection moulding machines without major modifications. The system detects when the mould is about to close and activates a vacuum to clear out trapped air just before injection. This results in better cavity filling, improved packing, and far fewer defects.

Unlike traditional passive venting approaches, which rely on air exiting the mould through the machined grooves and open channels that passively allow air to escape, this system uses sensors, a compact ejector, and a Programmable Logic Controller (commonly referred to as a PLC) to time the vacuuming process precisely. It was designed to work without needing full mould sealing, making it easier to install and more adaptable to different industrial setups. This approach fits the needs of today’s high-volume manufacturing, where speed and flexibility are essential.

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