Taguchi Optimization of Roundness and Concentricity of a Plastic Injection Molded Barrel of a Telecentric Lens

Plastic is an attractive material for the fabrication of tubular optical instruments due to its light weight, high strength, and ease of processing. However, for plastic components fabricated using the injection molding technique, roundness and concentricity remain an important concern. For example, in the case of a telecentric lens, concentricity errors of the lens barrel result in optical aberrations due to the deviation of the light path, while roundness errors cause radial stress due to the mismatch of the lens geometry during assembly. Accordingly, the present study applies the Taguchi design methodology to determine the optimal injection molding parameters which simultaneously minimize both the overall roundness and the overall concentricity of the optical barrel. The results show that the geometrical errors of the optical barrel are determined mainly by the melt temperature, the packing pressure, and the cooling time. The results also show that the optimal processing parameters reduce the average volume shrinkage rate (from 4.409% to 3.465%) and the average deformations from (0.592 mm to 0.469 mm) of the optical barrel, and the corresponding standard deviation values are reduced from 1.528% to 1.297% and from 0.263 mm to 0.211 mm, respectively. In addition, the overall roundness and overall concentricity of the barrel in the four planes are positively correlated.