Interactive robust optimal design of plastic injection products with minimum weldlines

  • Kwang-Ho Kim
  • Jong Cheon Park
  • Yong S. SuhEmail author
  • Bon-Heung Koo


A new robust optimal design methodology has been developed and applied to the design of plastic injection molding products. Taguchi’s robust design method and an optimal design search algorithm are integrated with a commercial CAE simulation tool. A direct search-based optimization procedure is implemented with the considerations of process variations as well as uncontrollable noise variables. The Interactive Design Space Reduction Method (IDSRM) based on orthogonal arrays for design of experiments is developed as a general optimization tool. Using the system, designers can interactively adjust the design space during the searching process for the optimal solution based on the outcomes of the experiments. The developed methodology is applied to an industrial application: a molding process design of an automobile front bumper to minimize the weldline, a form defect of plastic parts. Compared with the initial design solution, the optimized design aided by the proposed methodology shows a more efficient and better result in terms of design robustness against process variations.


Taguchi robust design Plastic injection molding Design space reduction method Design of experiments 


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Copyright information

© Springer-Verlag London 2016

Authors and Affiliations

  • Kwang-Ho Kim
    • 1
  • Jong Cheon Park
    • 1
  • Yong S. Suh
    • 2
    Email author
  • Bon-Heung Koo
    • 3
  1. 1.Department of Mechanical EngineeringKumoh National Institute of TechnologyGumiSouth Korea
  2. 2.Department of Mechanical EngineeringCalifornia State University, SacramentoSacramentoUSA
  3. 3.VM Tech, Co. LtdSuwonSouth Korea

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