Systems and methods for controlling injection molding using predicted cavity pressure

A method of controlling an injection molding machine, the method comprising:

• executing, by a controller, a calibration cycle in accordance with a mold cycle implemented by the injection molding machine;
• analyzing, by the controller, a plurality of sensed melt pressure values during the calibration cycle to determine one or more calibration metrics;
• executing, by the controller, a run using the injection molding machine, wherein the run sequentially implements the mold cycle a plurality of times;
• and
• during each mold cycle of the run:
• detecting, by the controller, a plurality of sensed melt pressures prior to and during a fill phase of the mold cycle;
• comparing, by the controller, the plurality of sensed melt pressures to the one or more calibration metrics to predict a cavity pressure for a pack and hold phase of the mold cycle;
• and
• adjust, by the controller, a set point pressure of the mold cycle for the pack and hold phase of the mold cycle based on the predicted cavity pressure.