Sensors Embedded in Surface Coatings in Injection Moulding Dies

This paper describes results from EU FP7 project IC2 and beyond using surface embedded in surface coatings in thermoplastics injection moulding dies. Sensors where fabricated on the surface of inserts on a bridge tool for injection moulding of a component using Direct Write Thermal Spray. The sensors were encapsulated in an Al2O3 layers for electrical insulation and wear resistance. The data from the sensors was used to calibrate the FEM sensors for calibration of FEM process simulation and optimisation of conformal cooling channels on the production tool.