Abstract
Injection-molded optical parts have been widely employed for various commercial electronic products in the market today. The large variations in thickness and stringent requirements in residual stresses have made the parts tough to manufacture. In this study, a true 3D CAE analysis incorporated with visco-elasticity models have been adopted for studies of typical cases. Some interesting phenomena during filling and packing of the parts have been predicted by the CAE simulations. Furthermore, experimental verifications on the phenomena have been conducted with reasonable accuracy not only in form accuracy but in residual stresses. Finally, the results have shown that residual stresses are mainly due to melt and injection speed whereas dimensional errors on part-surfaces are dependent of holding pressure and melt temperature during the molding process.