Gerald Berger-Weber

Institute of Injection Moulding of Polymers

The injection mold as a cyber physical system

Injection molded parts are formed in the mold cavity. To obtain a constant, disturbance-insensitive, and machine-independent part quality, it is crucial to be able to control the optimal process state of the polymer in the cavity from filling to demolding. This can be reached by evolving the injection mold to a cyber physical system. As a CPS, the injection mold is an equal and fully integrated partner of the modern injection molding machine. By employing artificial intelligence, OPC UA communication, transient sensor data from mold, machine, auxiliaries, and environment, as well as using the machine as an actuator, it monitors and controls shot-for-shot the spatiotemporal pressure, velocity and temperature field of the polymer in the cavity. After a training phase, it will identify automatically and react case-sensitively on many disturbances and process variations.

Gerald R. Berger-Weber studied Polymer Engineering & Science at the Montanuniversitaet Leoben, AUSTRIA. In 2002, his scientific career has started at the Polymer Competence Center Leoben (PCCL), AUSTRIA. He finished his PhD on „Replication of (micro)structured surfaces in injection molding“ in 2006. In 2010, he became PostDoc Assistant at the new founded Institute of Injection Molding of Polymers at the Montanuniversitaet Leoben. From 2014 to July 2018 he was Assistant Professor; he became Associate Professor in August 2018. His habilitation thesis provides a “View on Quality Optimization in Injection Molding”.
His field of research is process and part optimization in injection molding, emphasizing 1) process modelling and control, 2) dynamic mold temperature control, 3) surface topography and defects, 4) friction, and 5) reactive injection molding, respectively.