A self-tuning ultrasonic sensor based powder injection molding process

Ultrasonic sensors show great promise in defect detection and classification when monitoring the powder injection molding (PIM) manufacturing process. To date, however, these sensors are not used in a closed-loop control system. A simplex method is developed that automatically tunes a manufacturing system operating conditions on the basis of in situ ultrasonic sensor readings. Potential applications for this system include the initial set-up of optimal manufacturing conditions and also tracking of the optimum conditions in situ during long-term operation.