Largest Empty Corner Rectangle Based Process Development

A method for optimization of an injection molding cycle, the method comprising:

• obtaining, by a processor, a first plurality of step pressure versus step time data sets that define a low pressure versus step time curve in step pressure versus step time coordinate space;
• obtaining, by the processor, a second plurality of step pressure versus step time data sets that define a high pressure versus step time curve in step pressure versus step time coordinate space;
• defining, by the processor, two surfaces of a first geometric shape with the first surface of the first geometric shape being defined by the low pressure versus step time curve and the second surface of the geometric shape being defined by the high pressure versus step time curve, and a top surface and a bottom surface the top surface being defined by connecting the maximum pressure value data points of the first and second surfaces and the bottom surface being defined by connecting the minimum pressure value data points of the first and second surfaces;
• defining, by the processor, a plurality of geometric shapes within the first geometric shape and restricted by the first geometric shape in the step pressure versus step time coordinate space, wherein the geometric shapes in the plurality of geometric shapes have one vertex on the low pressure versus step time curve and one vertex on the high pressure versus step time curve;
• identifying, by the processor, a geometric shape of the plurality of geometric shapes having the largest area in the step pressure versus step time coordinate space;
• identifying, by the processor, a step pressure versus step time coordinate from inside of the identified geometric shape having the largest area;
• and
• configuring, by the processor, a controller of an injection molding machine to initiate a design of experiments process based on the identified step pressure versus step time coordinate by configuring a mold cycle profile that controls operation of the injection molding machine to include a step pressure value and a step time value indicated by the identified step pressure versus step time coordinate.