Usually, such a variable is selected based on the functionality of the injected parts. Additionally, it must be recognized that the optimized process parameters setting also depends strictly on the variable chosen in the experimental plan as the quality response. Hence, different methods such as the trial and error, analytical, and simulative methods are used to optimize the IM process parameters. At the same time, reaching the best process parameters setting is a very complex task due to the large number and types of involved factors. To this end, the selection of polymeric material is crucial since the type of monomer used directly affects the molding phase. In the IM process, the molten polymer is injected with a defined speed and pressure into a mold cavity assuming its shape here, both materials and process parameters play an essential role in producing high quality parts.

The results show that the surface parameters, evaluated in critical areas of the components, can ensure reliable estimates for the surface quality of the molded parts and can be preferred in comparison to linear measurements. To this aim, two experimental procedures were implemented to allow for: (i) the evaluation of the most suitable surface parameters identified in relation to the process parameters (ii) comparisons of the surface parameters findings with those obtained by classic dimensional quantity via a designed experimental plan (DoE). In this context, the present paper proposes the use of surface parameters as a quality index for the evaluation of both the micro injection molding process and the resulting products.

Therefore, in these cases, optical methods may be preferred for the evaluation of molded products’ dimensions and surface quality, especially for parts devoted to applications requiring functional purposes. Quality evaluation of micro injection molded products is a complex task, in particular when instruments basing on contact methods are used and issues in measurements could arise due to the contact tool dimension not fitting well with extremely narrow features.

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