Surface embedded temperature sensor on tool part for real time injection moulding process monitoring

This paper reports successful temperature measurements from a real time production process using surface integrated sensors. K-type thermocouples were fabricated directly on the surface of a tool part using Direct Write Thermal Spray and the process temperature cycle from an injection moulding process was measured under real running conditions. The metal-polymer interface never got hotter than 100°C as the >200°C molten polymer is instantly solidified as it reaches the cold metal surface.