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<p>Micro-structured plastic-metal hybrid (MPMH) components fabricated by insert injection molding are widely used in miniaturized optical modules because of their structural integration and multifunctional performance. However, the multi-stage processes from injection molding to subsequent thermal processing encountered by these components generate multi-stage deformation, posing significant challenges for understanding the underlying deformation mechanisms. In this study, we investigated the deformation of MPMH components during injection molding and thermal processing through numerical analysis and experimental study. A mold structure incorporating insert clamping blocks and insert positioning pins was designed to achieve preliminary positioning and fixation of the metal inserts. The effects of insert-induced cavity division, cavity geometry, and process parameters on pressure evolution, warpage, and asymmetric deformation as well as surface flatness in injection molding were analyzed. During thermal processing, deformation and temperature distribution were evaluated together with in-plane and through-thickness temperature gradients and the effect of heat-transfer modification. The evolution of the front-back flatness correlation from injection molding to thermal processing was also assessed. The results show that the metal insert unevenly divides the cavity and induces asymmetric deformation, leading to a pressure difference of up to 15.16&#xa0;MPa between the front and back sides. During thermal processing, the deformation is governed primarily by in-plane temperature non-uniformity rather than through-thickness temperature gradients, with a maximum in-plane temperature difference of 22.4&#xa0;°C. In addition, thermal processing increased the flatness correlation between the two surfaces from 0.452 after injection molding to 0.874 after thermal processing, indicating that the flatness responses of the two surfaces became more closely linked and suggesting deformation redistribution from injection molding to thermal processing. This study provides a basis for understanding the deformation mechanisms of MPMH components from injection molding to thermal processing, and offers guidance for process optimization, deformation adjustment, and dimensional stability improvement.</p>

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Deformation behavior of plastic-metal hybrid components for optical image stabilization: from injection molding to thermal processing

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年8月5日

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  • Hongpeng Fu,
  • Nanyang Zhao,
  • Haoyan Xu,
  • Jing Zhou,
  • Qiong Wu,
  • Wenwei Qiu,
  • Kaiwei Wang,
  • Zhongbin Xu

摘要

Micro-structured plastic-metal hybrid (MPMH) components fabricated by insert injection molding are widely used in miniaturized optical modules because of their structural integration and multifunctional performance. However, the multi-stage processes from injection molding to subsequent thermal processing encountered by these components generate multi-stage deformation, posing significant challenges for understanding the underlying deformation mechanisms. In this study, we investigated the deformation of MPMH components during injection molding and thermal processing through numerical analysis and experimental study. A mold structure incorporating insert clamping blocks and insert positioning pins was designed to achieve preliminary positioning and fixation of the metal inserts. The effects of insert-induced cavity division, cavity geometry, and process parameters on pressure evolution, warpage, and asymmetric deformation as well as surface flatness in injection molding were analyzed. During thermal processing, deformation and temperature distribution were evaluated together with in-plane and through-thickness temperature gradients and the effect of heat-transfer modification. The evolution of the front-back flatness correlation from injection molding to thermal processing was also assessed. The results show that the metal insert unevenly divides the cavity and induces asymmetric deformation, leading to a pressure difference of up to 15.16 MPa between the front and back sides. During thermal processing, the deformation is governed primarily by in-plane temperature non-uniformity rather than through-thickness temperature gradients, with a maximum in-plane temperature difference of 22.4 °C. In addition, thermal processing increased the flatness correlation between the two surfaces from 0.452 after injection molding to 0.874 after thermal processing, indicating that the flatness responses of the two surfaces became more closely linked and suggesting deformation redistribution from injection molding to thermal processing. This study provides a basis for understanding the deformation mechanisms of MPMH components from injection molding to thermal processing, and offers guidance for process optimization, deformation adjustment, and dimensional stability improvement.