Hybrid modeling approach for optimizing injection molding cycle time with PCR
A hybrid modeling approach combining physics-based and data-driven models to predict and minimize the impact of PCR content on injection molding cycle time, achieving over 95% accuracy and adaptability to new designs and machines.
Overview
This innovative hybrid modeling approach integrates physics-based models with data-driven methodologies to optimize the injection molding cycle time for PET containers, particularly when utilizing post-consumer recycled (PCR) material. By leveraging the complementary strengths of both modeling techniques, this solution achieves a prediction accuracy exceeding 95%. It dynamically adapts to new preform designs and machine types, ensuring robust and highly accurate predictions tailored to specific manufacturing contexts.
Technical specifications
Key features:
- Combines physics-based models (e.g., material science models, injection molding simulations) with data-driven models developed from historical data.
- Employs a rule-based stochastic decision-making algorithm and a hidden Markov model to enhance predictive accuracy and adaptability.
- Capable of dynamically updating models with minimal adjustments to rules or physics-based components, facilitating rapid adaptation to new tools and materials.
- Predicts and minimizes cycle time fluctuations due to varying PCR content, optimizing manufacturing efficiency.
Technology readiness level
Currently at TRL 5, this technology has been validated in relevant environments, with ongoing development to enhance its adaptability and accuracy. Future validation plans include developing a control model and human-machine interface (HMI) to recommend machine settings, further pushing the solution towards full commercialization.
About Clemson University
Clemson University is a comprehensive public land‑grant research university in Upstate South Carolina with a main campus and statewide outreach. Industry engages through co‑located facilities: an automotive innovation campus in Greenville, an energy testing complex in Charleston, and a research and technology park near the main campus with labs and offices. A strong co‑op program and corporate engagement team connect companies with faculty expertise and student talent, while the Extension network supports field trials and regional pilots. Research is backed by competitive federal funding from agencies such as NSF, NIH, DOE, USDA, and DOD. A dedicated technology transfer office provides IP, licensing, and startup support with clear pathways for industry‑sponsored agreements.
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