Performance Analysis of Enhanced 3D Printed Polymer Molds for Metal Injection Molding Process

Altaf, Khurram; Qayyum, Junaid; Rani, Ahmad Majdi Abdul; Ahmad, Faiz; Megat-Yusoff, Puteri Sri Melor; Baharom, Masri B.; Aziz, Abdul; Jahanzaib, Mirza; German, Randall M.

doi:10.3390/met8060433

Cited by 29 publications

(15 citation statements)

References 21 publications

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“…Injection molding is a common process for the shaping of thermoplastics [ 1 , 2 , 3 ], thermoplastic elastomers [ 4 , 5 , 6 ], composites [ 7 , 8 , 9 ], as well as metals [ 10 , 11 , 12 ] and ceramics [ 13 , 14 ]. The central concept around the method is the melting and plasticization of the material and feeding it into a mold cavity, where the material is solidified by cooling [ 15 ].…”

Section: Introductionmentioning

confidence: 99%

Sensorized Robotic Skin Based on Piezoresistive Sensor Fiber Composites Produced with Injection Molding of Liquid Silicone

2021

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Soft robotics and flexible electronics are rising in popularity and can be used in many applications. However, there is still a need for processing routes that allow the upscaling in production for functional soft robotic parts in an industrial scale. In this study, injection molding of liquid silicone is suggested as a fabrication method for sensorized robotic skin based on sensor fiber composites. Sensor fibers based on thermoplastic elastomers with two different shore hardness (50A and 70A) are combined with different silicone materials. A mathematical model is used to predict the mechanical load transfer from the silicone matrix to the fiber and shows that the matrix of the lowest shore hardness should not be combined with the stiffer fiber. The sensor fiber composites are fixed on a 3D printed robotic finger. The sensorized robotic skin based on the composite with the 50A fiber in combination with pre-straining gives good sensor performance as well as a large elasticity. It is proposed that a miss-match in the mechanical properties between fiber sensor and matrix should be avoided in order to achieve low drift and relaxation. These findings can be used as guidelines for material selection for future sensor integrated soft robotic systems.

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Section: Introductionmentioning

confidence: 99%

Sensorized Robotic Skin Based on Piezoresistive Sensor Fiber Composites Produced with Injection Molding of Liquid Silicone

2021

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“…In today's competitive environment, waste and cost reduction is one of the primary objectives of any manufacturing concern. 1–3 The use of 3D printed parts for small production with variety of products as well as design variation on one table is also a very important factor in the product design and development. 4–6 Some researchers have reported acceptable load-bearing properties of 3D printed parts for uses in construction.…”

Section: Introductionmentioning

confidence: 99%

Mechanical and morphological investigations of 3D printed recycled ABS reinforced with bakelite–SiC–Al₂O₃

Singh

Kumar

2019

Proceedings of the Institution of Mechanical Engineers, Part C:

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The utilization of thermosetting waste is a serious issue as it is not recycled commercially due to inherent molecular properties and high technology cost. This research details the study of the mechanical behavior and surface analysis with energy-dispersive X-ray spectroscopy and scanning electron microscope of three-dimensional printed parts of the waste thermosetting polymer, bakelite (BAK) as the reinforcement along with ceramic particles (SiC and Al2O3) in recycled thermoplastic acrylonitrile butadiene styrene matrix for sustainability. The process involves twin-screw extrusion for the preparation of filament, followed by 3D printing of functional prototypes on fused deposition modeling setup. The 3D printed parts prepared with fused deposition modeling were used for the testing of mechanical, thermal, and morphological properties. The results of the present study suggests that for commercial applications recycling of thermoplastic up to 10 wt% can be easily performed without a change in any hardware/ software configuration of the fused deposition modeling setup and the ceramic concentration in thermoplastic-thermosetting blends further led to better mechanical and surface properties.

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“…Other works studying MJT tooling compared it to conventional metal tooling [ 12 , 13 ], powder bed fusion (PBF) AM tooling [ 12 ] and resin-casting tooling [ 14 ]. Tooling made via fused filament fabrication (FFF), which is an AM process from the MEX category, was studied, e.g., for use in metal injection molding [ 15 ] and in a study describing the development of a process-specific FFF soft tooling material [ 16 ]. A good overview of the state-of-the-art concerning soft tooling in the context of tooling for injection molding is given by Dizon et al [ 17 ].…”

Section: Introductionmentioning

confidence: 99%

Feasibility Study of Soft Tooling Inserts for Injection Molding with Integrated Automated Slides

et al. 2021

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The production of injection-molding prototypes, e.g., molded interconnect devices (MID) prototypes, can be costly and time-consuming due to the process-specific inability to replace durable steel tooling with quicker fabricated aluminum tooling. Instead, additively manufactured soft tooling is a solution for the production of small quantities and prototypes, but producing complex parts with, e.g., undercuts, is avoided due to the necessity of additional soft tooling components. The integration of automated soft slides into soft tooling has not yet been investigated and poses a challenge for the design and endurance of the tooling. The presented study covers the design and injection-molding trial of soft tooling with integrated automated slides for the production of a complex MID prototype. The design further addresses issues like the alignment of the mold components and the sealing of the complex parting plane. The soft tooling was additively manufactured via digital light processing from a silica-filled photopolymer, and 10 proper parts were injection-molded from a laser-direct structurable glass fiber-filled PET+PBT material before the first damage on the tooling occurred. Although improvements are suggested to enhance the soft tooling durability, the designed features worked as intended and are generally transferable to other part geometries.

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Performance Analysis of Enhanced 3D Printed Polymer Molds for Metal Injection Molding Process

Cited by 29 publications

References 21 publications

Sensorized Robotic Skin Based on Piezoresistive Sensor Fiber Composites Produced with Injection Molding of Liquid Silicone

Sensorized Robotic Skin Based on Piezoresistive Sensor Fiber Composites Produced with Injection Molding of Liquid Silicone

Mechanical and morphological investigations of 3D printed recycled ABS reinforced with bakelite–SiC–Al₂O₃

Feasibility Study of Soft Tooling Inserts for Injection Molding with Integrated Automated Slides

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Performance Analysis of Enhanced 3D Printed Polymer Molds for Metal Injection Molding Process

Cited by 29 publications

References 21 publications

Sensorized Robotic Skin Based on Piezoresistive Sensor Fiber Composites Produced with Injection Molding of Liquid Silicone

Sensorized Robotic Skin Based on Piezoresistive Sensor Fiber Composites Produced with Injection Molding of Liquid Silicone

Mechanical and morphological investigations of 3D printed recycled ABS reinforced with bakelite–SiC–Al2O3

Feasibility Study of Soft Tooling Inserts for Injection Molding with Integrated Automated Slides

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Mechanical and morphological investigations of 3D printed recycled ABS reinforced with bakelite–SiC–Al₂O₃