Date Approved


Graduate Degree Type


Degree Name

Engineering (M.S.E.)

Degree Program

School of Engineering

First Advisor

Wael Mokhtar

Second Advisor

Chris Pung

Third Advisor

Sunghwan Joo

Academic Year



Plastic Injection Molding (PIM) is one of the leading manufacturing processes in the industrial revolution. It is important to have defect-free molded products from this process. This study shows that injection molded parts defect can be addressed and resolved through numerical and statical analysis. Warpage and short shot are destructive defects for injection molded products. The reduction of these two defects was the goal of this study. The numerical analysis was done using Moldex3D software. The Taguchi Design of Experiment (DOE) was followed to optimize the input parameters and reduce the selected defects. Three levels of each parameter were selected. Four factors and three levels led to nine cases for single design matrix. Nine cases of simulation for amorphous material and nine cases of simulation for semi-crystalline material were run in Moldex3D. To measure the warpage defect, warpage displacement was listed. To measure short shot, total part weight was listed. Signal-to-Noise (SN) was calculated for each design case. To determine the most significant factor, Analysis of Variance (ANOVA) was performed. This study improved warpage defect at a significant level but short shot defect was improved at small percentage. It is also shown that the analysis is low cost. In addition, it can be resolved in a small-time span.

Available for download on Tuesday, December 17, 2024