Multi-factor optimization on metal injection molding in orthodontic single brackets manufacturing.
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| Title: | Multi-factor optimization on metal injection molding in orthodontic single brackets manufacturing. |
|---|---|
| Authors: | Rosli, Mohd Uzair1 (AUTHOR) uzair@unimap.edu.my, Khor, Chu Yee1 (AUTHOR) |
| Source: | International Journal of Advanced Manufacturing Technology. Apr2026, Vol. 143 Issue 11/12, p7171-7185. 15p. |
| Subjects: | Injection molding of metals, Process optimization, Experimental design, Orthodontic appliances, Response surfaces (Statistics) |
| Abstract: | Metal injection molding (MIM) offers a cost-effective route for fabricating orthodontic brackets, yet quality control is often hindered by defects such as shrinkage, warpage, and incomplete filling arising from complex process–parameter interactions. While previous studies have optimized numerical parameters, the role of categorical factors like injection location remains underexplored. This study integrates Moldflow simulation with Response Surface Methodology (RSM) to optimize critical MIM parameters such as mold temperature, melt temperature, flow rate, and injection location for single orthodontic brackets. A Central Composite Design (CCD) was employed to establish predictive models for three responses: time to ejection temperature, volumetric shrinkage, and cavity fill. The optimized condition of 25 °C mold temperature, 137.89 °C melt temperature, 127.56 cm³/s flow rate, and bottom injection, minimized shrinkage and filling defects. Validation showed prediction–simulation differences below 3%, within acceptable engineering tolerance. This work bridges a critical gap by demonstrating how injection location governs rheological behavior, cooling efficiency, and shrinkage distribution factors often overlooked in conventional MIM optimization. Findings provide a robust computational framework for defect minimization and dimensional control in orthodontic MIM components, offering manufacturers a practical tool to reduce reliance on costly trial-and-error and support more reliable, efficient bracket production. [ABSTRACT FROM AUTHOR] |
| Copyright of International Journal of Advanced Manufacturing Technology is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.) | |
| Database: | Engineering Source |
| FullText | Text: Availability: 0 |
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| Header | DbId: egs DbLabel: Engineering Source An: 193841306 AccessLevel: 6 PubType: Academic Journal PubTypeId: academicJournal PreciseRelevancyScore: 0 |
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| Items | – Name: Title Label: Title Group: Ti Data: Multi-factor optimization on metal injection molding in orthodontic single brackets manufacturing. – Name: Author Label: Authors Group: Au Data: <searchLink fieldCode="AR" term="%22Rosli%2C+Mohd+Uzair%22">Rosli, Mohd Uzair</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> uzair@unimap.edu.my</i><br /><searchLink fieldCode="AR" term="%22Khor%2C+Chu+Yee%22">Khor, Chu Yee</searchLink><relatesTo>1</relatesTo> (AUTHOR) – Name: TitleSource Label: Source Group: Src Data: <searchLink fieldCode="JN" term="%22International+Journal+of+Advanced+Manufacturing+Technology%22">International Journal of Advanced Manufacturing Technology</searchLink>. Apr2026, Vol. 143 Issue 11/12, p7171-7185. 15p. – Name: Subject Label: Subjects Group: Su Data: <searchLink fieldCode="DE" term="%22Injection+molding+of+metals%22">Injection molding of metals</searchLink><br /><searchLink fieldCode="DE" term="%22Process+optimization%22">Process optimization</searchLink><br /><searchLink fieldCode="DE" term="%22Experimental+design%22">Experimental design</searchLink><br /><searchLink fieldCode="DE" term="%22Orthodontic+appliances%22">Orthodontic appliances</searchLink><br /><searchLink fieldCode="DE" term="%22Response+surfaces+%28Statistics%29%22">Response surfaces (Statistics)</searchLink> – Name: Abstract Label: Abstract Group: Ab Data: Metal injection molding (MIM) offers a cost-effective route for fabricating orthodontic brackets, yet quality control is often hindered by defects such as shrinkage, warpage, and incomplete filling arising from complex process–parameter interactions. While previous studies have optimized numerical parameters, the role of categorical factors like injection location remains underexplored. This study integrates Moldflow simulation with Response Surface Methodology (RSM) to optimize critical MIM parameters such as mold temperature, melt temperature, flow rate, and injection location for single orthodontic brackets. A Central Composite Design (CCD) was employed to establish predictive models for three responses: time to ejection temperature, volumetric shrinkage, and cavity fill. The optimized condition of 25 °C mold temperature, 137.89 °C melt temperature, 127.56 cm³/s flow rate, and bottom injection, minimized shrinkage and filling defects. Validation showed prediction–simulation differences below 3%, within acceptable engineering tolerance. This work bridges a critical gap by demonstrating how injection location governs rheological behavior, cooling efficiency, and shrinkage distribution factors often overlooked in conventional MIM optimization. Findings provide a robust computational framework for defect minimization and dimensional control in orthodontic MIM components, offering manufacturers a practical tool to reduce reliance on costly trial-and-error and support more reliable, efficient bracket production. [ABSTRACT FROM AUTHOR] – Name: AbstractSuppliedCopyright Label: Group: Ab Data: <i>Copyright of International Journal of Advanced Manufacturing Technology is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.) |
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| RecordInfo | BibRecord: BibEntity: Identifiers: – Type: doi Value: 10.1007/s00170-026-17826-y Languages: – Code: eng Text: English PhysicalDescription: Pagination: PageCount: 15 StartPage: 7171 Subjects: – SubjectFull: Injection molding of metals Type: general – SubjectFull: Process optimization Type: general – SubjectFull: Experimental design Type: general – SubjectFull: Orthodontic appliances Type: general – SubjectFull: Response surfaces (Statistics) Type: general Titles: – TitleFull: Multi-factor optimization on metal injection molding in orthodontic single brackets manufacturing. Type: main BibRelationships: HasContributorRelationships: – PersonEntity: Name: NameFull: Rosli, Mohd Uzair – PersonEntity: Name: NameFull: Khor, Chu Yee IsPartOfRelationships: – BibEntity: Dates: – D: 20 M: 04 Text: Apr2026 Type: published Y: 2026 Identifiers: – Type: issn-print Value: 02683768 Numbering: – Type: volume Value: 143 – Type: issue Value: 11/12 Titles: – TitleFull: International Journal of Advanced Manufacturing Technology Type: main |
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