Rapid Tooling Injection Molded Prototypes: A Case Study in Artificial Photosynthesis Technology

Noble, Joanna; Walczak, Karl; Dornfeld, David

doi:10.1016/j.procir.2014.03.035

Cited by 36 publications

(22 citation statements)

References 3 publications

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“…RT is a process that uses AM techniques to build tools at low cost. RT negates the need for complex conventional machining operations and direct labor, and instead uses an additive approach of building objects layer by layer [12,13]. The initial push for developing objects quickly without the need for complex tooling came from the American automotive industry [14].…”

Section: Polymer Rapid Tooling (Prt)mentioning

confidence: 99%

Categorization of Failures in Polymer Rapid Tools Used for Injection Molding

et al. 2019

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Background—Polymer rapid tooling (PRT) inserts for injection molding (IM) are a cost-effective method for prototyping and low-volume manufacturing. However, PRT inserts lack the robustness of steel inserts, leading to progressive deterioration and failure. This causes quality issues and reduced part numbers. Approach—Case studies were performed on PRT inserts, and different failures were observed over the life of the tool. Parts molded from the tool were examined to further understand the failures, and root causes were identified. Findings—Critical parameters affecting the tool life, and the effect of these parameters on different areas of tool are identified. A categorization of the different failure modes and the underlying mechanisms are presented. The main failure modes are: surface deterioration; surface scalding; avulsion; shear failure; bending failure; edge failure. The failure modes influence each other, and they may be connected in cascade sequences. Originality—The original contributions of this work are the identification of the failure modes and their relationships with the root causes. Suggestions are given for prolonging tool life via design practices and molding parameters.

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Section: Polymer Rapid Tooling (Prt)mentioning

confidence: 99%

Categorization of Failures in Polymer Rapid Tools Used for Injection Molding

et al. 2019

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“…Most promising and reliable applications of 3D printed molds are related to highly tailored but low-volume part demand. 3D printed polymer molds could be used for indirect rapid tooling for such demand [2]. Nevertheless, if the part demand is low, 3D printed polymer molds could be viable for direct rapid tools, whereas the machine mold could become redundant due to low demand.…”

Section: Of 17mentioning

confidence: 99%

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

Altaf

Qayyum

Rani

et al. 2018

Metals

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Conventionally, molds for metal injection molding (MIM) process are fabricated using metallic materials using conventional machining processes. Machined metal molds are resilient and therefore could be suitable for mass production of MIM parts. However, with the process of mass production leading to permanent hard tooling, the design is subjected to rigorous testing and iteration before finalization. During design analysis and the iteration process, the demand for MIM parts (part demand) is at low-volume. Therefore, machined metal molds could be costly and time consuming for low volume and customized end-use products. 3D printed molds could be a suitable choice for MIM production for such applications. The present study compares the performance of Fused Deposition Modelling (FDM) 3D printing (3DP) process made polymer molds with an aluminum mold for potential use in MIM process. It was observed that 3DP molds could successfully be used for a limited number of MIM cycles.

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“…The PIM process is a cyclic one which consists of¯lling and packing, cooling and ejection. 1 Injection molding helps in producing products for computer, communication and consumer electronic (3C) such as portable computers and cell phones. The 3C products are generally thin, light, short and small.…”

Section: Introductionmentioning

confidence: 99%

Warpage and Shrinkage Analysis and Optimization of Rapid Tooling Molded thin Wall Component Using Modified Particle Swarm Algorithm

Kumar

Singh

2019

J. Adv. Manuf. Syst.

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This paper presents a systematic methodology to determine optimal injection molding conditions for minimum warpage and shrinkage in a thin wall relay part using modified particle swarm optimization algorithm (MPSO). Polybutylene terephthalate (PBT) and polyethylene terephthalate (PET) were injected in a thin wall relay component for different processing parameters: melt temperature, packing pressure and packing time. Further, Taguchi’s L9 (3[Formula: see text] orthogonal array is used for conducting simulation analysis to consider the interaction effects of the above parameters. A predictive mathematical model for shrinkage and warpage is developed in terms of the above process parameters using regression analysis. ANOVA analysis is performed to establish statistical significance within the injection molding parameters. The analytical model is further optimized using a newly developed MPSO algorithm and the process parameters values are predicted for minimizing shrinkage and warpage. The predicted values of shrinkage and warpage using MPSO algorithm are improved by approximately 30% as compared to the initial simulation values and comparable to previous literature results.

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Rapid Tooling Injection Molded Prototypes: A Case Study in Artificial Photosynthesis Technology

Cited by 36 publications

References 3 publications

Categorization of Failures in Polymer Rapid Tools Used for Injection Molding

Categorization of Failures in Polymer Rapid Tools Used for Injection Molding

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

Warpage and Shrinkage Analysis and Optimization of Rapid Tooling Molded thin Wall Component Using Modified Particle Swarm Algorithm

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