This study presents a breakthrough in sustainable injection molding by uniquely combining a backpropagation neural network (BPNN) with particle swarm optimization (PSO) to overcome traditional optimization challenges. The BPNN’s exceptional ability to learn complex nonlinear relationships between six key process parameters (including melt temperature and holding pressure) and product quality is amplified by PSO’s intelligent search capability, which efficiently navigates the high-dimensional parameter space. Together, this hybrid approach achieves what neither method could accomplish alone: the BPNN accurately models the intricate process-quality relationships, while PSO rapidly converges on optimal parameter sets that simultaneously meet strict quality targets (66–70 g weight, 3–5 mm thickness) and minimize energy consumption. The significance of this integration is demonstrated through three key outcomes: First, the BPNN-PSO combination reduced optimization time by 40% compared to traditional trial-and-error methods. Second, it achieved remarkable prediction accuracy (RMSE 0.8229 for thickness, 1.5123 for weight) that surpassed standalone BPNN implementations. Third, the method’s efficiency enabled SMEs to achieve CAE-level precision without expensive software, reducing setup costs by approximately 25%. Experimental validation confirmed that the optimized parameters decreased energy use by 28% and material waste by 35% while consistently producing parts within specifications. This research provides manufacturers with a practical, scalable solution that transforms injection molding from an experience-dependent craft to a data-driven science. The BPNN-PSO framework not only delivers superior technical results but does so in a way that is accessible to resource-constrained manufacturers, marking a significant step toward sustainable, intelligent production systems. For SMEs, this framework offers a practical pathway to achieve both economic and environmental sustainability, reducing reliance on resource-intensive CAE tools while cutting production costs by an estimated 22% through waste and energy savings. The study provides a replicable blueprint for implementing data-driven sustainability in injection molding operations without compromising product quality or operational efficiency.
Jou et al. (Tue,) studied this question.