Evolution of additively manufactured injection molding inserts investigated by thermal simulations

Hofstätter, Thomas; Pedersen, David Bue; Tosello, Guido; Hansen, Hans Nørgaard

doi:10.1063/1.5088311

Cited by 5 publications

(8 citation statements)

References 7 publications

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“…For example as reported in [15] and [16]. Inserts manufactured from carbon fiber reinforced photopolymer has withstood up to 2500 injection molding cycles for polyethylene before noticeable mold deterioration was observed [17]. This soft tooling process chain is suitable for production in intermediate production volumes (e.g.…”

Section: Introductionmentioning

confidence: 81%

A Soft Tooling process chain employing Additive Manufacturing for injection molding of a 3D component with micro pillars

Zhang

Pedersen

Gøtje

et al. 2017

Journal of Manufacturing Processes

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The purpose of the research presented in this paper is to investigate the capability of a soft tooling process chain employing Additive Manufacturing (AM) for preproduction of an insert with micro features by injection moulding. The Soft Tooling insert was manufactured in a high temperature photopolymer by Digital Light Processing (vat photopolymerization). The mold cavity was formed by two insert halves, by design; both inserts have four angled tines, with micro holes (Ø200 µm, 200 µm deep) on the surface. Injection molding with polyethylene was used with the soft tool inserts to manufacture the final production components. The diameter and height of the pillars that were replicated on the molded components were characterized by means of a 3D profilometer. The influence of the injection molding parameters on the replication was evaluated using a 2-levels DOE of three factors. The uniformity of the pillars are also evaluated regarding the diameter and height.

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Section: Introductionmentioning

confidence: 81%

A Soft Tooling process chain employing Additive Manufacturing for injection molding of a 3D component with micro pillars

Zhang

Pedersen

Gøtje

et al. 2017

Journal of Manufacturing Processes

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“…The AM inserts have been manufactured according to [6,8] using the commercially available photopolymer resin HTM-140v2 and a bottom-up machine in a "hanging" configuration meaning that the printed layers were oriented in Proceedings of PPS-34 AIP Conf. Proc.…”

Section: Methodsmentioning

confidence: 99%

“…These cracks propagate deeper and longer through the insert. The reason for this behavior is the missing connection between the layers reducing the crack propagation velocity as investigated during the IM process in [8]. As an example, measured surface cracks are shown in Figure 4 (left) showing a smaller penetration of the insert than aligned cracks shown in Figure 4 (right).…”

Section: Figurementioning

confidence: 99%

“…By improving the fiber-matrix-interface and optimizing process parameters in both the additive manufacturing (AM) vat photopolymerization (VP) process as well as the IM cycle with additional cooling mechanisms (both forced and free convection) [4], the lifetime of the named inserts has been improved up to 4,500 shots. A significant challenge mentioned in several investigations [5,8] was introduced by the layer-wise orientation of CFs due to process parameters including build plate movement and print orientation, as well as flow patterns. While a theoretical approach was conducted in [8], this contribution investigates the end-of-life parameters of a used IM insert, which was kept in the production cycle twice as long as the usual lifetime.…”

Section: Introductionmentioning

confidence: 99%

“…A significant challenge mentioned in several investigations [5,8] was introduced by the layer-wise orientation of CFs due to process parameters including build plate movement and print orientation, as well as flow patterns. While a theoretical approach was conducted in [8], this contribution investigates the end-of-life parameters of a used IM insert, which was kept in the production cycle twice as long as the usual lifetime. Data analysis was conducted using X-ray computed tomography in order to gain fiber orientation, fiber volume fraction, crack orientation, crack length, width, depth, and air intrusions.…”

Section: Introductionmentioning

confidence: 99%

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Internal fiber structure of a high-performing, additively manufactured injection molding insert

Hofstätter¹,

Baier²,

Trinderup³

et al. 2019

AIP Conference Proceedings

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A standard mold is equipped with additively manufactured inserts in a rectangular shape produced with vat photo polymerization. While the lifetime compared to conventional materials such as brass, steel, and aluminum is reduced, the prototyping and design phase can be shortened significantly by using flexible and cost-effective additive manufacturing technologies. Higher production volumes still exceed the capability of additively manufactured inserts, which are overruled by the stronger performance of less-flexible but mechanically advanced materials. In this contribution, the internal structure of a high-performing, fiber-reinforced injection molding insert has been analyzed. The insert reached a statistically proven and reproducible lifetime of 4,500 shots, which significantly outperforms any other previously published additively manufactured inserts. Computer tomography, tensile tests and life cycle analysis have been performed in order to provide an understanding of the internal structure of the fiber-reinforced, additively manufactured injection molding inserts.

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Review and Development of Design Guidelines for Additive Tooling of Injection Molds Using PolyJet Modelling

Junk,

Schrock,

Schmieder

2023

Springer Tracts in Additive Manufacturing

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Due to globalization and the resulting increase in competition on the market, products must be produced more and more cheaply, especially in series production, because buyers expect new variants or even completely new products in ever shorter cycles. Injection molding is the most important production process for manufacturing plastic components in large quantities. However, the conventional production of a mold is extremely time-consuming and costly, which creates a contradiction to the fast pace of the market. Additive tooling is an area of application of additive manufacturing, which in the field of injection molding is preferably used for the prototype production of mold inserts. This allows injection molding tools to be produced faster and more cheaply than through the subtractive manufacturing of metal tools. Material Jetting processes using polymers (MJT-UV/P), also called Polyjet Modeling (PJM), have a great potential for use in additive tooling. Due to the poorer mechanical and thermal properties compared to conventional mold insert materials, e.g. steel or aluminum, the previously used design principles cannot be applied. Accordingly, new design guidelines are necessary, which are developed in this paper. The necessary information is obtained with the help of a systematic literature research. The design guidelines are mapped in a uniform design guide, which is structured according to the design process of injection molds. The guidelines do not only refer to the constructive design of the injection mold or the polymer mold insert, but to the entire design process and describe the four phases of planning, conception, development and realization. Particular attention is paid to the special geometric designs of a polymer mold insert and the thermomechanical properties of the mold insert materials. As a result, design guidelines are available that are adapted to the special requirements of additive tooling of molds inserts made of plastics for injection molding.

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Evolution of additively manufactured injection molding inserts investigated by thermal simulations

Cited by 5 publications

References 7 publications

A Soft Tooling process chain employing Additive Manufacturing for injection molding of a 3D component with micro pillars

A Soft Tooling process chain employing Additive Manufacturing for injection molding of a 3D component with micro pillars

Internal fiber structure of a high-performing, additively manufactured injection molding insert

Review and Development of Design Guidelines for Additive Tooling of Injection Molds Using PolyJet Modelling

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