{"status":"ok","message-type":"work","message-version":"1.0.0","message":{"indexed":{"date-parts":[[2026,9,15]],"date-time":"2026-09-15T13:08:56Z","timestamp":1789477736318,"version":"build-2803163510"},"reference-count":129,"publisher":"MDPI AG","issue":"8","license":[{"start":{"date-parts":[[2025,4,18]],"date-time":"2025-04-18T00:00:00Z","timestamp":1744934400000},"content-version":"vor","delay-in-days":0,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0\/"}],"funder":[{"name":"Bayerisches Staatsministerium f\u00fcr Wirtschaft, Landesentwicklung und Energie (StMWi), Zentrum Digitalisierung.Bayern (ZD.B), and Sumitomo (SHI) Demag Plastics Machinery GmbH","award":["DIK0392\/02"],"award-info":[{"award-number":["DIK0392\/02"]}]},{"name":"Rosenheim Technical University of Applied Sciences","award":["DIK0392\/02"],"award-info":[{"award-number":["DIK0392\/02"]}]}],"content-domain":{"domain":[],"crossmark-restriction":false},"short-container-title":["Polymers"],"abstract":"<jats:p>Thermoplastic injection molding is a widely used process for producing complex three-dimensional plastic parts with tight dimensional tolerances. A key determinant of part quality is the switchover point\u2014the transition from velocity-controlled filling to pressure-controlled packing. This transition affects critical product attributes, such as d imensional accuracy, weight consistency, and surface finish. Precise control of the switchover point enhances process stability, robustness, and adaptability. This review consolidates recent advancements in switchover methods and adaptive control techniques. Improvements in traditional methods include the use of pressure gradient detection to mitigate viscosity variations and adaptive control to refine stroke- and time-dependent switchovers. In addition, deformation-based strategies detect the mold-opening force associated with cavity pressure through clamping force, mold separation, or tie-bar elongation. The integration of machine learning and feature extraction techniques enables the real-time adjustment of the switchover point by mapping relationships between process parameters and quality criteria. In addition, ultrasonic sensors provide non-invasive melt front detection, reducing the risk of mold damage. Real-time simulations, updated through nozzle pressure feedback, complement these methods to achieve precise switchover timing. This review also identifies persistent challenges, such as sensitivity to material properties, machine wear, and environmental conditions, and it explores future directions for improving the accuracy and adaptability of switchover control in modern injection molding processes.<\/jats:p>","DOI":"10.3390\/polym17081096","type":"journal-article","created":{"date-parts":[[2025,4,18]],"date-time":"2025-04-18T06:23:56Z","timestamp":1744957436000},"page":"1096","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":12,"title":["From Manual to Automated: Exploring the Evolution of Switchover Methods in Injection Molding Processes\u2014A Review"],"prefix":"10.3390","volume":"17","author":[{"given":"Christian","family":"Bielenberg","sequence":"first","affiliation":[{"name":"Department of Plastics Technology, Faculty of Engineering Sciences, Rosenheim Technical University of Applied Sciences, Hochschulstra\u00dfe 1, 83024 Rosenheim, Germany"},{"name":"Faculty of Mechanical Science and Engineering, TUD Dresden University of Technology, Helmholtzstr. 10, 01062 Dresden, Germany"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-0406-5800","authenticated-orcid":false,"given":"Markus","family":"Stommel","sequence":"additional","affiliation":[{"name":"Faculty of Mechanical Science and Engineering, TUD Dresden University of Technology, Helmholtzstr. 10, 01062 Dresden, Germany"},{"name":"Institute Polymer Materials, Leibniz-Institute for Polymer Research Dresden, Hohe Stra\u00dfe 6, 01127 Dresden, Germany"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Peter","family":"Karlinger","sequence":"additional","affiliation":[{"name":"Department of Plastics Technology, Faculty of Engineering Sciences, Rosenheim Technical University of Applied Sciences, Hochschulstra\u00dfe 1, 83024 Rosenheim, Germany"}],"role":[{"vocabulary":"crossref","role":"author"}]}],"member":"1968","published-online":{"date-parts":[[2025,4,18]]},"reference":[{"key":"ref_1","doi-asserted-by":"crossref","first-page":"159","DOI":"10.1016\/j.jmapro.2019.09.005","article-title":"Monitoring, prediction and control of injection molding quality based on tie-bar elongation","volume":"46","author":"Chen","year":"2019","journal-title":"J. Manuf. Process."},{"key":"ref_2","doi-asserted-by":"crossref","first-page":"123332","DOI":"10.1016\/j.polymer.2020.123332","article-title":"Enhancing the quality stability of injection molded parts by adjusting V\/P switchover point and holding pressure","volume":"213","author":"Chen","year":"2021","journal-title":"Polymer"},{"key":"ref_3","doi-asserted-by":"crossref","first-page":"121788","DOI":"10.1016\/j.ijheatmasstransfer.2021.121788","article-title":"Determination of process parameters based on cavity pressure characteristics to enhance quality uniformity in injection molding","volume":"180","author":"Chen","year":"2021","journal-title":"Int. J. Heat Mass Transf."},{"key":"ref_4","doi-asserted-by":"crossref","first-page":"1273","DOI":"10.1080\/03602559.2011.578292","article-title":"Filling-To-Packing Switchover Mode Based on Cavity Temperature for Injection Molding","volume":"50","author":"Wang","year":"2011","journal-title":"Polym.-Plast. Technol. Eng."},{"key":"ref_5","doi-asserted-by":"crossref","unstructured":"Heinzler, F.A. (2014). Modellgest\u00fctzte Qualit\u00e4tsregelung Durch Eine Adaptive, Druckgeregelte Prozessf\u00fchrung Beim Spritzgie\u00dfen. [Ph.D. Thesis, Universit\u00e4t Duisburg-Essen].","DOI":"10.3139\/O999.02032015"},{"key":"ref_6","doi-asserted-by":"crossref","first-page":"114163","DOI":"10.1016\/j.measurement.2024.114163","article-title":"Measurement techniques in injection molding: A comprehensive review of machine status detection, molten resin flow state characterization, and component quality adjustment","volume":"226","author":"Zhao","year":"2024","journal-title":"Measurement"},{"key":"ref_7","doi-asserted-by":"crossref","unstructured":"Ageyeva, T., Horv\u00e1th, S., and Kov\u00e1cs, J.G. (2019). In-Mold Sensors for Injection Molding: On the Way to Industry 4.0. Sensors, 19.","DOI":"10.3390\/s19163551"},{"key":"ref_8","doi-asserted-by":"crossref","unstructured":"Liew, K.-F., Peng, H.-S., Huang, P.-W., and Su, W.-J. (2022). Injection Barrel\/Nozzle\/Mold-Cavity Scientific Real-Time Sensing and Molding Quality Monitoring for Different Polymer-Material Processes. Sensors, 22.","DOI":"10.3390\/s22134792"},{"key":"ref_9","doi-asserted-by":"crossref","unstructured":"Liou, G.-Y., Cheng, F.-J., Su, W.-J., Hwang, S.-J., Peng, H.-S., and Chu, H.-Y. (2022, January 18\u201321). Nozzle Pressure and Clamping Force Based Injection Molding Process Parameter Optimization and Adaptive Process Quality Control. Proceedings of the 2022 25th International Conference on Mechatronics Technology (ICMT), Kaohsiung, Taiwan.","DOI":"10.1109\/ICMT56556.2022.9997782"},{"key":"ref_10","doi-asserted-by":"crossref","unstructured":"Liou, G.-Y., Su, W.-J., Cheng, F.-J., Chang, C.-H., Tseng, R.-H., Hwang, S.-J., Peng, H.-S., and Chu, H.-Y. (2023). Optimize Injection-Molding Process Parameters and Build an Adaptive Process Control System Based on Nozzle Pressure Profile and Clamping Force. Polymers, 15.","DOI":"10.3390\/polym15030610"},{"key":"ref_11","doi-asserted-by":"crossref","first-page":"107526","DOI":"10.1016\/j.polymertesting.2022.107526","article-title":"Optimization process parameters and adaptive quality monitoring injection molding process for materials with different viscosity","volume":"109","author":"Su","year":"2022","journal-title":"Polym. Test."},{"key":"ref_12","doi-asserted-by":"crossref","unstructured":"Fan-Jiang, J.-C., Su, C.-W., Liou, G.-Y., Hwang, S.-J., Lee, H.-H., Peng, H.-S., and Chu, H.-Y. (2021). Study of an Online Monitoring Adaptive System for an Injection Molding Process Based on a Nozzle Pressure Curve. Polymers, 13.","DOI":"10.3390\/polym13040555"},{"key":"ref_13","unstructured":"Edwards, R., Diao, L., Thomas, C.L., and Groleau, M. (2002, January 5\u20139). Cavity Based Ultrasonic Resonance Monitoring in Injection Molding. Proceedings of the ANTEC, San Francisco, CA, USA."},{"key":"ref_14","doi-asserted-by":"crossref","first-page":"118","DOI":"10.1016\/j.sna.2018.11.009","article-title":"On-line measurement of cavity pressure during injection molding via ultrasonic investigation of tie bar","volume":"285","author":"Zhang","year":"2019","journal-title":"Sens. Actuators A Phys."},{"key":"ref_15","doi-asserted-by":"crossref","first-page":"1436","DOI":"10.1016\/j.polymertesting.2013.09.006","article-title":"Non-destructive measurement of cavity pressure during injection molding process based on ultrasonic technology and Gaussian process","volume":"32","author":"Zhao","year":"2013","journal-title":"Polym. Test."},{"key":"ref_16","unstructured":"Huang, M.-S., Nian, S.-C., and Chen, J.-Y. (2019, January 18\u201321). Tie-bar elongation based prediction of injection molding quality. Proceedings of the ANTEC, Detroit, MI, USA."},{"key":"ref_17","doi-asserted-by":"crossref","unstructured":"Chen, J.-Y., Liu, C.-Y., and Huang, M.-S. (2019). Tie-Bar Elongation Based Filling-To-Packing Switchover Control and Prediction of Injection Molding Quality. Polymers, 11.","DOI":"10.3390\/polym11071168"},{"key":"ref_18","doi-asserted-by":"crossref","first-page":"154","DOI":"10.1115\/1.1540126","article-title":"Modeling and Control of an Electro-hydraulic Injection Molding Machine with Smoothed Fill-to-Pack Transition","volume":"125","author":"Zheng","year":"2003","journal-title":"J. Manuf. Sci. Eng."},{"key":"ref_19","unstructured":"Schwarz, O., Ebeling, F.W., and Furth, B. (2009). Kunststoffverarbeitung, Vogel. [11th ed.]."},{"key":"ref_20","doi-asserted-by":"crossref","unstructured":"Sch\u00f6tz, A. (2013). Abmusterung von Spritzgie\u00dfwerkzeugen: Strukturierte und Analytische Vorgehensweise, Hanser, Carl.","DOI":"10.3139\/9783446436114.fm"},{"key":"ref_21","doi-asserted-by":"crossref","unstructured":"Jaroschek, C. (2024). Injection Molding for Practitioners, Hanser.","DOI":"10.3139\/9781569902929"},{"key":"ref_22","first-page":"30","article-title":"Offensichtliche Fortschritte und Verborgene Sch\u00e4tze","volume":"12","author":"Jaroschek","year":"2013","journal-title":"Kunststoffe"},{"key":"ref_23","first-page":"309","article-title":"Analysis of Cavity Pressure and Dimension of Molded Part According to V\/P Switchover Position in Injection Molding","volume":"52","author":"Cho","year":"2017","journal-title":"Elastomers Compos."},{"key":"ref_24","doi-asserted-by":"crossref","unstructured":"Nian, S.-C., Fang, Y.-C., and Huang, M.-S. (2019). In-mold and Machine Sensing and Feature Extraction for Optimized IC-tray Manufacturing. Polymers, 11.","DOI":"10.3390\/polym11081348"},{"key":"ref_25","doi-asserted-by":"crossref","unstructured":"Jaroschek, C. (2024). Spritzgie\u00dfen f\u00fcr Praktiker, Hanser. [5th ed.].","DOI":"10.3139\/9783446480568"},{"key":"ref_26","doi-asserted-by":"crossref","unstructured":"Kulkarni, S. (2024). Robust Process Development and Scientific Molding: Theory and Practice, Hanser. [3rd ed.].","DOI":"10.3139\/9781569909096"},{"key":"ref_27","doi-asserted-by":"crossref","first-page":"2031","DOI":"10.1002\/pen.21731","article-title":"A comparison of seven filling to packing switchover methods for injection molding","volume":"50","author":"Kazmer","year":"2010","journal-title":"Polym. Eng. Sci."},{"key":"ref_28","doi-asserted-by":"crossref","unstructured":"Knoll, J., and Heim, H.-P. (2023). Analysis of the Machine-Specific Behavior of Injection Molding Machines. Polymers, 16.","DOI":"10.3390\/polym16010054"},{"key":"ref_29","unstructured":"Kazmer, D. (2010). Robustness of Switchover Methods for Injection Molding, Society of Plastics Engineers (SPE)."},{"key":"ref_30","unstructured":"Kudlik, N. (1998). Reproduzierbarkeit des Kunststoff-Spritzgie\u00dfprozesses, Mainz. [1st ed.]."},{"key":"ref_31","doi-asserted-by":"crossref","first-page":"137","DOI":"10.1002\/adv.1983.060030208","article-title":"Using ram velocity to control IMM part quality","volume":"3","author":"Aloise","year":"1983","journal-title":"Adv. Polym. Technol."},{"key":"ref_32","unstructured":"Diao, L., Edwards, R., and Thomas, C.L. (2003, January 4\u20138). A Comparison of Position, Cavity Pressure, and Ultrasound Sensors for Switch\/Over Control in Injection Molding. Proceedings of the Annual Technical Conference of the Society of Plastics Engineers, Nashville, TN, USA."},{"key":"ref_33","unstructured":"Altonen, G.M., Neufarth, R.E., Schiller, G.F., and Berg, C.J. (2014). Alternative Pressure Control for an Injection Molding Apparatus. (US 2014\/0255530 A1), Patent."},{"key":"ref_34","unstructured":"Santini, K. (2024, June 18). Addressing the Challenge of Injection Molding Regrind\u2014Recycling Today: Imux Technology Helps Injection Molders Increase Their Use of Recycled Plastics. Available online: https:\/\/www.recyclingtoday.com\/article\/addressing-the-challenge-of-injection-molding-regrind\/."},{"key":"ref_35","first-page":"e00651","article-title":"Investigation of pressure-controlled injection molding on the mechanical properties and embodied energy of recycled high-density polyethylene","volume":"36","author":"Krantz","year":"2023","journal-title":"Sustain. Mater. Technol."},{"key":"ref_36","unstructured":"kunststoffFORUM (2024, July 05). ENGEL X-MELT: Pr\u00e4zisions-Mikrospritzguss mit der Vollelektrischen Standardmaschine. Available online: http:\/\/www.kunststoffforum.de\/information\/news_artikel.php?id=3084."},{"key":"ref_37","unstructured":"Steinbichler, G., and Pokorny, P. (1999). Injection Moulding Process. (EP 1 074 374 A1), Patent."},{"key":"ref_38","doi-asserted-by":"crossref","first-page":"419","DOI":"10.1016\/j.jmatprotec.2006.10.037","article-title":"Cavity pressure based grey prediction of the filling-to-packing switchover point for injection molding","volume":"183","author":"Huang","year":"2007","journal-title":"J. Mater. Process. Technol."},{"key":"ref_39","unstructured":"Chang, T.C. (2002, January 5\u20139). Process Capability Comparison of Various Switchover Modes from the Filling to Packing Stages in Injection Molding. Proceedings of the ANTEC, San Francisco, CA, USA."},{"key":"ref_40","first-page":"239","article-title":"Robust process control in injection molding\u2014Process capability comparison for five switchover modes","volume":"6","author":"Chang","year":"2002","journal-title":"J. Inject. Molding Technol."},{"key":"ref_41","unstructured":"Offergeld, H. (1990). Verfahren und Vorrichtung zur Optimierung der Schneckenvorlaufgeschwindigkeit beim Umschalten zwischen Einspritzphase und Nachdruckphase beim Spritzgie\u00dfen. (DE 40 11 230 A1), Patent."},{"key":"ref_42","unstructured":"Schubert, A. (2009, January 22\u201324). A Comparison of velocity to pressure transfer control strategies for injection molding. Proceedings of the ANTEC, Chicago, IL, USA."},{"key":"ref_43","unstructured":"Johnson, B. (2013, January 22\u201324). Determining Which In-Mold Sensors Should Be Used for V\/P Transfer During Injection Molding for Three Different Injection Strategies. Proceedings of the ANTEC, Cincinnati, OH, USA."},{"key":"ref_44","unstructured":"Johnson, B. (2019, January 18\u201321). Novel V\/P Transfer Actuation Method and Injection Molding Strategy and Their Comparison to Traditional Methods. Proceedings of the ANTEC, Detroit, MI, USA."},{"key":"ref_45","unstructured":"Schiffers, R. (2009). Verbesserung der Prozessf\u00e4higkeit Beim Spritzgie\u00dfen Durch Nutzung von Prozessdaten und Eine Neuartige Schneckenhubf\u00fchrung. [Ph.D. Thesis, University of Duisburg-Essen]."},{"key":"ref_46","unstructured":"Holzinger, G.P., Kruppa, S., Moser, S., and Schiffers, R. (2014, January 28\u201330). An Adaptive Filling to Packing Switchover Method for Injection Molding. Proceedings of the 72nd Annual Technical Conference of the Society of Plastics Engineers, Las Vegas, NV, USA."},{"key":"ref_47","unstructured":"Ghose, A., Montero, M., and Odell, D. (2001). Characterization of an Injection Molding Process for Improved Part Quality. Eng. Mater. Sci., Available online: http:\/\/ode11.com\/projects\/tricon_report.pdf."},{"key":"ref_48","first-page":"30","article-title":"Abgeleitete Kenngr\u00f6\u00dfen zur Optimierung nutzen","volume":"99","author":"Gornik","year":"2009","journal-title":"Kunststoffe"},{"key":"ref_49","unstructured":"Eben, J. (2014). Identifikation und Reduzierung realer Schwankungen durch Praxistaugliche Prozessf\u00fchrungsmethoden beim Spritzgie\u00dfen. [Ph.D. Thesis, Technische Universit\u00e4t Chemnitz]."},{"key":"ref_50","doi-asserted-by":"crossref","unstructured":"Hopmann, C., Menges, G., Michaeli, W., and Mohren, P. (2018). Spritzgie\u00dfwerkzeuge: Auslegung, Bau, Anwendung, Hanser. [7th ed.].","DOI":"10.1007\/978-3-446-45390-6"},{"key":"ref_51","unstructured":"Baesso, R., and Lucchetta, G. (2008, January 4\u20138). Switchover control in the polymer injection forming process. Proceedings of the 66th Annual Technical Conference of the Society of Plastics Engineers 2008, Milwaukee, WI, USA."},{"key":"ref_52","unstructured":"Cooney, R., Neill, D., and Pomorski, L. (2001, January 6\u201310). An Investigation of Part Variation in Multi-Cavity Injection Molds When Using Cavity Pressure Control. Proceedings of the ANTEC 2001 Conference Proceedings, Dallas, TX, USA."},{"key":"ref_53","doi-asserted-by":"crossref","first-page":"1865","DOI":"10.1002\/pen.11837","article-title":"Multi-cavity pressure control in the filling and packing stages of the injection molding process","volume":"37","author":"Kazmer","year":"1997","journal-title":"Polym. Eng. Sci."},{"key":"ref_54","doi-asserted-by":"crossref","first-page":"1880","DOI":"10.1002\/pen.11838","article-title":"The process capability of multi-cavity pressure control for the injection molding process","volume":"37","author":"Kazmer","year":"1997","journal-title":"Polym. Eng. Sci."},{"key":"ref_55","first-page":"42","article-title":"Qualit\u00e4tssicherung f\u00fcr viele Kavit\u00e4ten: Prozessregelung automatisiert Spritzgie\u00dfprozesse\u2014Hier am Beispiel eines W\u00fcrfelwerkzeugs","volume":"6","author":"Ortgies","year":"2021","journal-title":"Kunststoffe"},{"key":"ref_56","unstructured":"Schiffers, R., Holzinge, G., and Huster, G. (2016, January 8\u201310). Adaptive process control for stabilizing the production process in injection moulding machines. Proceedings of the 10th International Fluid Power Conference, Dresden, Germany."},{"key":"ref_57","unstructured":"Albertson, A.S., and Brendel, M.V. (2002, January 5\u20139). Investigation of Injection Molding Process Robustness for Various Molding Strategies. Proceedings of the ANTEC, San Francisco, CA, USA."},{"key":"ref_58","doi-asserted-by":"crossref","first-page":"51223","DOI":"10.1002\/app.51223","article-title":"Influence of V\/P switchover point, injection speed, and holding pressure on quality consistency of injection-molded parts","volume":"138","author":"Huang","year":"2021","journal-title":"J. Appl. Polym. Sci."},{"key":"ref_59","doi-asserted-by":"crossref","first-page":"1665","DOI":"10.1109\/TCST.2019.2918993","article-title":"Model-Predictive Control of Servo-Pump Driven Injection Molding Machines","volume":"28","author":"Froehlich","year":"2020","journal-title":"IEEE Trans. Contr. Syst. Technol."},{"key":"ref_60","doi-asserted-by":"crossref","first-page":"451","DOI":"10.1080\/13873954.2018.1481870","article-title":"Control-oriented modeling of servo-pump driven injection molding machines in the filling and packing phase","volume":"24","author":"Froehlich","year":"2018","journal-title":"Math. Comput. Model. Dyn. Syst."},{"key":"ref_61","first-page":"82","article-title":"Die Umschaltproblematik und ihre Folgen: Phasenlose Prozessregelung soll den Umschaltvorgang revolutionieren","volume":"3","author":"Hopmann","year":"2020","journal-title":"Kunststoffe"},{"key":"ref_62","doi-asserted-by":"crossref","unstructured":"Stemmler, S., Ay, M., Vukovic, M., Abel, D., Heinisch, J., and Hopmann, C. (2019, January 19\u201321). Cross-phase Model-based Predictive Cavity Pressure Control in Injection Molding. Proceedings of the 2019 IEEE Conference on Control Technology and Applications (CCTA), Hong Kong, China.","DOI":"10.1109\/CCTA.2019.8920461"},{"key":"ref_63","unstructured":"Hornberg, K., Hopmann, C., Vukovic, M., Stemmler, S., and Abel, D. (2023, January 27\u201330). Compensation of batch fluctuations of post-consumer recyclate in injection molding by phase-unifying process control. Proceedings of the SPE ANTEC 2023, Denver, CO, USA."},{"key":"ref_64","unstructured":"Hertz, R.A., Christensen, J.K., Therkelsen, O., Kristiansen, S., Helver, C.-E., Hansson, F.A., and Schmidt, L. (2023, January 27\u201330). A Novel Approach to Control Switchover Between Injection and Holding Phase for a Hydraulic Injection Moulding Machine. Proceedings of the 2023 SPE Annual Technical Conference and Exhibition, ANTEC 2023, Denver, CO, USA."},{"key":"ref_65","doi-asserted-by":"crossref","unstructured":"Lin, C.-Y., Shen, F.-C., Wu, K.-T., Hwang, S.-J., and Lee, H.-H. (2019, January 3\u20136). Injection Molding Process Control of Servo-Hydraulic System. Proceedings of the 2019 IEEE Eurasia Conference on IOT, Communication and Engineering (ECICE), Yunlin, Taiwan.","DOI":"10.1109\/ECICE47484.2019.8942784"},{"key":"ref_66","first-page":"72","article-title":"Arbeit an der Spitze: Das Schlie\u00dfverhalten von R\u00fcckstromsperren","volume":"6","author":"Gornik","year":"2001","journal-title":"Kunststoffe"},{"key":"ref_67","unstructured":"Schiffers, R., Moser, S., and Kruppa, S. (2013). Method for Volumetrically Correct Filling of Cavity of Molding Tool with Melt of Material to Be Processed in Injection Molding Process, Involves Providing Injection Molding Machine Equipped with Molding Tool. (DE 10 2013 111 257 B3), Patent."},{"key":"ref_68","first-page":"58","article-title":"F\u00fcr jeden Schuss der richtige Umschaltpunkt","volume":"11","author":"Schiffers","year":"2014","journal-title":"Kunststoffe"},{"key":"ref_69","unstructured":"(2024, October 11). activeLock\u2014Sumitomo (SHI) Demag. Available online: https:\/\/www.sumitomo-shi-demag.eu\/activelock."},{"key":"ref_70","unstructured":"Runge, R. (2008). Verfahren zur Steuerung des Einspritzhubes Einer Spritzgie\u00df-Schnecke. (DE 10 2008 037 098 A1), Patent."},{"key":"ref_71","first-page":"70","article-title":"Gesteuerter Schlie\u00dfvorgang, h\u00f6chste Gewichtskonstanz","volume":"8","author":"Schmied","year":"2013","journal-title":"Kunststoffe"},{"key":"ref_72","unstructured":"(2024, June 20). Pr\u00e4zisionsspritzguss f\u00fcr Kunststoff-Produkte\u2014ENGEL. Available online: https:\/\/www.engelglobal.com\/de\/de\/produkte\/spritzgiessverfahren\/praezisionsspritzguss."},{"key":"ref_73","unstructured":"Schmied, M. (2012). R\u00fcckstromsperre f\u00fcr eine Plastifizierschnecke einer Spritzgie\u00dfmaschine. (DE 10 2012 015 337 A1), Patent."},{"key":"ref_74","unstructured":"(2024, October 11). Xaloy\u00ae Front End Components, USA. Available online: https:\/\/xaloy.com\/download\/front-end-components-data-sheet\/?tmstv=1728641978."},{"key":"ref_75","unstructured":"Hiroshi, W., and Shingo, K. (2003). Injection Molding Machine Having a Freely Rotatable Screw. (US 7,074,028 B2), Patent."},{"key":"ref_76","doi-asserted-by":"crossref","first-page":"811","DOI":"10.1002\/pen.26246","article-title":"Study on the evaluation and compensating strategy for the wear damage of non-return valve during injection molding process","volume":"63","author":"Ma","year":"2023","journal-title":"Polym. Eng. Sci."},{"key":"ref_77","unstructured":"Liu, J. (2010). Erh\u00f6hung der Reproduzierbarkeit des Spritzgie\u00dfprozesses durch verbesserte Plastifizierkonzepte. [Ph.D. Thesis, Technische Universit\u00e4t M\u00fcnchen]."},{"key":"ref_78","doi-asserted-by":"crossref","unstructured":"P\u00e1rizs, R.D., T\u00f6r\u00f6k, D., Ageyeva, T., and Kov\u00e1cs, J.G. (2023). Multiple In-Mold Sensors for Quality and Process Control in Injection Molding. Sensors, 23.","DOI":"10.3390\/s23031735"},{"key":"ref_79","unstructured":"Bader, C., Greco, L., Christopherus, B., and Luigi, G. (1995). Process to Determine the Switch-Over Point in the Production of an Injection-Moulded Part. (EP 0 707 936 (A2)), Patent."},{"key":"ref_80","unstructured":"Gao, F., and Zhao, C. (1998). Method and Apparatus for the Control of Injection Molding. (US 6,309,571 B2), Patent."},{"key":"ref_81","doi-asserted-by":"crossref","first-page":"191","DOI":"10.1002\/adv.20097","article-title":"An integrated intelligent system for injection molding process determination","volume":"26","author":"Zhou","year":"2007","journal-title":"Adv. Polym. Technol."},{"key":"ref_82","unstructured":"Huang, M.-S. (2001). Process for Determining the Switchover Point from the Filling Program to the Holding Program in the Injection Molding Process. (TW000000529995B), Patent."},{"key":"ref_83","unstructured":"Chen, K.-C., and Huang, M.-S. (2013). A process for Determining the Switchover Point from the Filling Program to the Holding Program in the Injection Molding. (TW00000I495428B), Process. Patent."},{"key":"ref_84","unstructured":"Scheckenbach, T., and Wieland, R. (1991). Verfahren und Vorrichtung zur Regelung eines Spritzgie\u00dfprozesses. (DE 41 40 392 C2), Patent."},{"key":"ref_85","doi-asserted-by":"crossref","unstructured":"Tseng, R.-H., Wen, C.-H., Chang, C.-H., Chen, Y.-H., Tsai, C.-H., and Hwang, S.-J. (2025). Nozzle Pressure- and Screw Position-Based CAE Scientific Process Parameter Setup for Injection Molding Process. Polymers, 17.","DOI":"10.3390\/polym17020198"},{"key":"ref_86","doi-asserted-by":"crossref","unstructured":"Cheng, F.-J., Chang, C.-H., Wen, C.-H., Hwang, S.-J., Peng, H.-S., and Chu, H.-Y. (2024). Out-of-Mold Sensor-Based Process Parameter Optimization and Adaptive Process Quality Control for Hot Runner Thin-Walled Injection-Molded Parts. Polymers, 16.","DOI":"10.3390\/polym16081057"},{"key":"ref_87","doi-asserted-by":"crossref","first-page":"439","DOI":"10.1016\/j.cirpj.2020.07.006","article-title":"Data-driven smart control of injection molding process","volume":"31","author":"Kumar","year":"2020","journal-title":"CIRP J. Manuf. Sci. Technol."},{"key":"ref_88","unstructured":"Pillwein, G. (2011). Verfahren zur Quantifizierung von Prozessschwankungen bei Einem einspritzvorgang Einer Spritzgiessmaschine. (AT 511 391 A1), Patent."},{"key":"ref_89","first-page":"31","article-title":"Einfaches Umschalten auf konstante Qualit\u00e4t","volume":"9","author":"Pillwein","year":"2012","journal-title":"Kunststoffe"},{"key":"ref_90","unstructured":"Koppauer, H., Pillwein, G., Springer, K., and Kilian, F.J. (2019). Verfahren zum Festlegen eines Sollwertverlaufs. (AT 523126 A1), Patent."},{"key":"ref_91","unstructured":"Sasaki, K., Kato, F., Totani, T., Iimura, Y., Koike, J., Tamaki, M., and Yamaguchi, M. (1998). Controlling Method of Switchover of Injection Speed for Electric Injection Molding Machine. (11348084 A), Patent."},{"key":"ref_92","doi-asserted-by":"crossref","first-page":"23","DOI":"10.1179\/146580100101540662","article-title":"In process monitoring of polymer batch to batch variation in injection moulding","volume":"29","author":"Kelly","year":"2000","journal-title":"Plast. Rubber Compos."},{"key":"ref_93","unstructured":"Kruppa, S. (2015). Adaptive Prozessf\u00fchrung und alternative Einspritzkonzepte beim Spritzgie\u00dfen von Thermoplasten. [Ph.D. Thesis, Universit\u00e4t Duisburg-Essen]."},{"key":"ref_94","unstructured":"KraussMaffei Technologies GmbH (2017). APC Plus: Stabilit\u00e4t, Pr\u00e4zision und Kosteneffizienz in der Fertigung, KraussMaffei Technologies GmbH."},{"key":"ref_95","unstructured":"Schiffers, R., Moser, S., Kruppa, S., and Busl, M. (2015). Verfahren zur Bestimmung eines realen Volumens einer spritzgie\u00dff\u00e4higen Masse in einem Spritzgie\u00dfprozess. (DE 10 2015 117 237 B3), Patent."},{"key":"ref_96","unstructured":"Gao, H., Huang, Z., Li, D., Mao, T., Zhang, Y., Zhou, H., and Zhoun, X. (2014). Dynamic Adjustment Method for Plastic Injection Moulding Pressure-Keeping Switchover. (CN000104626494A), Patent."},{"key":"ref_97","doi-asserted-by":"crossref","first-page":"358","DOI":"10.1016\/j.jmatprotec.2017.05.038","article-title":"Monitoring and dynamic control of quality stability for injection molding process","volume":"249","author":"Zhou","year":"2017","journal-title":"J. Mater. Process. Technol."},{"key":"ref_98","doi-asserted-by":"crossref","first-page":"383","DOI":"10.1177\/1461348419875057","article-title":"Adaptive process control of the changeover point for injection molding process","volume":"40","author":"Chen","year":"2019","journal-title":"J. Low Freq. Noise Vib. Act. Control."},{"key":"ref_99","doi-asserted-by":"crossref","first-page":"1114","DOI":"10.1002\/pen.25910","article-title":"Self-optimization of the V\/P switchover and packing pressure for online viscosity compensation during injection molding","volume":"62","author":"Xu","year":"2022","journal-title":"Polym. Eng. Sci."},{"key":"ref_100","doi-asserted-by":"crossref","first-page":"1081","DOI":"10.1002\/pen.760311502","article-title":"Advanced process control for injection molding","volume":"31","author":"Smud","year":"1991","journal-title":"Polym. Eng. Sci."},{"key":"ref_101","unstructured":"Moritzer, E., and Neumann, M. (1999, January 2\u20136). Process Monitoring and Optimisation in Injection Moulding with the Aid of New Measuring Sensors. Proceedings of the ANTEC, New York, NY, USA."},{"key":"ref_102","doi-asserted-by":"crossref","first-page":"569","DOI":"10.1002\/pen.20509","article-title":"Adaptive online quality control for injection-molding by monitoring and controlling mold separation","volume":"46","author":"Chen","year":"2006","journal-title":"Polym. Eng. Sci."},{"key":"ref_103","doi-asserted-by":"crossref","first-page":"852","DOI":"10.1002\/pen.20769","article-title":"Injection molding quality control by integrating weight feedback into a cascade closed-loop control system","volume":"47","author":"Chen","year":"2007","journal-title":"Polym. Eng. Sci."},{"key":"ref_104","doi-asserted-by":"crossref","unstructured":"Zhang, P., Xie, P., and Yang, W. (2010, January 26\u201328). Study on mold separation-based precision injection molding method. Proceedings of the 2010 International Conference on Mechanic Automation and Control Engineering (MACE), Wuhan, China.","DOI":"10.1109\/MACE.2010.5536370"},{"key":"ref_105","first-page":"42","article-title":"Nur noch volle Teile","volume":"102","author":"Jaeger","year":"2012","journal-title":"Kunststoffe"},{"key":"ref_106","doi-asserted-by":"crossref","first-page":"564","DOI":"10.3139\/217.3867","article-title":"Enhancement of Injection Molding Consistency by Adjusting Velocity\/Pressure Switching Time Based on Clamping Force","volume":"34","author":"Chen","year":"2019","journal-title":"Int. Polym. Process."},{"key":"ref_107","unstructured":"Engel Austria GmbH (2021). Simulation Combined with the Real World: ENGEL Sim Link Data Interface Extended to Include CADMOULD, Engel Austria GmbH."},{"key":"ref_108","unstructured":"Wagner, P.J., and Pillwein, G. (2019). Verfahren zum Bestimmen realer Formmassenfronten und zum Abgleich von Simulationen. (AT 523127 A1), Patent."},{"key":"ref_109","unstructured":"Arburg GmbH + Co., KG. (2024). aXw Control FillAssist: Unterst\u00fctzung von F\u00fcllstudien mit F\u00fcllbilddarstellung 682206_DE_012021, Arburg GmbH + Co. KG."},{"key":"ref_110","first-page":"158","article-title":"Sehen, was im Werkzeug passiert","volume":"10","author":"Duffner","year":"2019","journal-title":"Kunststoffe"},{"key":"ref_111","doi-asserted-by":"crossref","first-page":"2482","DOI":"10.1002\/pen.21481","article-title":"Online simulation-based process control for injection molding","volume":"49","author":"Johnston","year":"2009","journal-title":"Polym. Eng. Sci."},{"key":"ref_112","doi-asserted-by":"crossref","first-page":"956","DOI":"10.1007\/s00170-002-1417-9","article-title":"Application of Neural Networks in Injection Moulding Process Control","volume":"21","author":"Huang","year":"2003","journal-title":"Int. J. Adv. Manuf. Technol."},{"key":"ref_113","doi-asserted-by":"crossref","first-page":"765","DOI":"10.1007\/s00170-014-5711-0","article-title":"A nondestructive online method for monitoring the injection molding process by collecting and analyzing machine running data","volume":"72","author":"Zhao","year":"2014","journal-title":"Int. J. Adv. Manuf. Technol."},{"key":"ref_114","doi-asserted-by":"crossref","first-page":"50","DOI":"10.1016\/j.jmatprotec.2018.05.026","article-title":"Feature extraction and physical interpretation of melt pressure during injection molding process","volume":"261","author":"Zhou","year":"2018","journal-title":"J. Mater. Process. Technol."},{"key":"ref_115","doi-asserted-by":"crossref","first-page":"528","DOI":"10.1016\/j.jmapro.2019.12.020","article-title":"A hybrid back-propagation neural network and intelligent algorithm combined algorithm for optimizing microcellular foaming injection molding process parameters","volume":"50","author":"Guo","year":"2020","journal-title":"J. Manuf. Process."},{"key":"ref_116","doi-asserted-by":"crossref","first-page":"2511","DOI":"10.1002\/pen.25777","article-title":"Calibration of cavity pressure simulation using autoencoder and multilayer perceptron neural networks","volume":"61","author":"Huang","year":"2021","journal-title":"Polym. Eng. Sci."},{"key":"ref_117","doi-asserted-by":"crossref","unstructured":"Tsai, M.-H., Fan-Jiang, J.-C., Liou, G.-Y., Cheng, F.-J., Hwang, S.-J., Peng, H.-S., and Chu, H.-Y. (2022). Development of an Online Quality Control System for Injection Molding Process. Polymers, 14.","DOI":"10.3390\/polym14081607"},{"key":"ref_118","doi-asserted-by":"crossref","unstructured":"Wu, D.-R., Ong, J.-B., Chen, Y.-J., Li, J.-C., Peng, H.-S., and Wei, L.-J. (2023, January 27\u201329). Study of Application of Taguchi\u2019s Method and Neural Networks to Molding Characteristics Predictions. Proceedings of the 2023 IEEE 5th Eurasia Conference on IOT, Communication and Engineering (ECICE), Yunlin, Taiwan.","DOI":"10.1109\/ECICE59523.2023.10383007"},{"key":"ref_119","doi-asserted-by":"crossref","first-page":"851","DOI":"10.1016\/j.procir.2023.06.146","article-title":"Approach for inline monitoring and optimization of a thermoplastic injection molding process with Bayesian networks taking the example of the quality feature weight","volume":"118","author":"Borchardt","year":"2023","journal-title":"Procedia CIRP"},{"key":"ref_120","unstructured":"Johnson, B. (2019, January 18\u201321). Evaluation of Novel Switch to Detect the Melt Flow Front in Injection Molding. Proceedings of the ANTEC, Detroit, MI, USA."},{"key":"ref_121","doi-asserted-by":"crossref","unstructured":"M\u00fcller, F., Kukla, C., Lucyshyn, T., Harker, M., Rath, G., and Holzer, C. (2014). Wireless in-mold melt front detection for injection molding: A long-term evaluation. J. Appl. Polym. Sci., 131.","DOI":"10.1002\/app.40346"},{"key":"ref_122","unstructured":"Gornik, C. (2007). Injection Molding Method Comprises Determining Compressibility and Flowability of Molding Composition and Calculating Content of Binder in Composition or Homogeneity of the Binder-Filler Mixture from This Data. (DE 10 2007 030 637 A1), Patent."},{"key":"ref_123","unstructured":"Pillwein, G. (2015). Bestimmungsverfahren f\u00fcr das Kompressionsverhalten eines formbaren Materials. (AT 517128 A1), Patent."},{"key":"ref_124","doi-asserted-by":"crossref","unstructured":"Moniz, N., Vale, Z., Cascalho, J., Silva, C., and Sebasti\u00e3o, R. (2023). Advancements in Synthetic Data Extraction for Industrial Injection Molding. Progress in Artificial Intelligence, Springer Nature.","DOI":"10.1007\/978-3-031-49011-8"},{"key":"ref_125","unstructured":"Topi\u0107, N. (2022). Auswirkungen der Styrolemission Unges\u00e4ttigter Polyesterharze Auf Die Eigenschaften spritzgegossener Formteile. [Ph.D. Thesis, Friedrich-Alexander-Universit\u00e4t Erlangen-N\u00fcrnberg]."},{"key":"ref_126","doi-asserted-by":"crossref","first-page":"4288","DOI":"10.1002\/pen.26847","article-title":"Processing recycled silicone powder in liquid silicone rubber injection molding and its influence on mechanical properties","volume":"64","author":"Mayer","year":"2024","journal-title":"Polym. Eng. Sci."},{"key":"ref_127","doi-asserted-by":"crossref","first-page":"174","DOI":"10.3139\/217.970174","article-title":"Determination of the Inter-Relationships Between Processing Conditions and Properties of an Injection Molded Silicone Ring Using an Experimental Design","volume":"12","author":"Barbaroux","year":"1997","journal-title":"Int. Polym. Process."},{"key":"ref_128","doi-asserted-by":"crossref","first-page":"R96","DOI":"10.1088\/0960-1317\/17\/6\/R02","article-title":"Microinjection molding of thermoplastic polymers: A review","volume":"17","author":"Giboz","year":"2007","journal-title":"J. Micromech. Microeng."},{"key":"ref_129","doi-asserted-by":"crossref","first-page":"1542","DOI":"10.1002\/pen.10130","article-title":"Effects of process parameters on the micro molding process","volume":"43","author":"Zhao","year":"2003","journal-title":"Polym. Eng. Sci."}],"container-title":["Polymers"],"original-title":[],"language":"en","link":[{"URL":"https:\/\/www.mdpi.com\/2073-4360\/17\/8\/1096\/pdf","content-type":"unspecified","content-version":"vor","intended-application":"similarity-checking"}],"deposited":{"date-parts":[[2025,10,9]],"date-time":"2025-10-09T17:17:16Z","timestamp":1760030236000},"score":1,"resource":{"primary":{"URL":"https:\/\/www.mdpi.com\/2073-4360\/17\/8\/1096"}},"subtitle":[],"short-title":[],"issued":{"date-parts":[[2025,4,18]]},"references-count":129,"journal-issue":{"issue":"8","published-online":{"date-parts":[[2025,4]]}},"alternative-id":["polym17081096"],"URL":"https:\/\/doi.org\/10.3390\/polym17081096","relation":{},"ISSN":["2073-4360"],"issn-type":[{"value":"2073-4360","type":"electronic"}],"subject":[],"published":{"date-parts":[[2025,4,18]]}}}