Characterization and control of plastic deformation in premolded components in in-mold assembled mesoscale revolute joints using bi-directional filling strategy

One of the major challenges associated with the in-mold assembly processes at the mesoscale is the interaction between the polymer melt and the premolded components that are present in the mold. When a high speed, high temperature second stage melt comes in contact with a premolded mesoscale component having similar melting temperatures, the premolded component undergoes thermal softening and plastic deformation. To overcome this challenge we have developed a novel, multi gate mold design allowing for bidirectional filling. The bi-directional filling balances forces applied on the premolded component by the polymer melt flow. This paper presents experimental results and a preliminary model to understand the sensitivity of gate location to 1) location of weld lines and 2) force responsible for the plastic deformation of the premolded mesoscale component.