3D Printed Injection Molds Using Various 3D Printing Technologies

Abstract

This paper explores the possibility of using different 3d printing methods and materials in the production of polymer molds for injection molding applications. A mold producing a cube was designed using a commercial software. Following the standard 3d printing process, injection molds which could produce a cube were printed using different 3d printing materials and 3d printing technologies. The 3d printing technologies used were Stereolithography (SLA), Polyjet and Fused Filament Fabrication (FFF). A bench-top injection molding machine was used to inject polylactic acid (PLA) in these molds. The quality of the injected parts in terms of dimensional accuracy has been investigated. In some cases, the damage mechanism of the polymer molds has also been observed.

Micro Injection Molding of Thin Cavities Using Stereolithography for Mold Fabrication

“…The weakness of the SLA molds was referred to as cracking, and chipping mechanisms occurred after 60 shots, which were mainly attributed to transverse tension and the thermal cycle, whereas layer delamination strongly limited (10 shots) the endurance of the FDM 3D-printed mold inserts. Again, the same authors [ 10 ] conducted injection molding tests with SLA, polyjet, and FDM mold inserts. A PEEK mold fabricated by FDM showed delamination, whereas mold inserts made by SLA and polyjet technologies showed good surface finishing and acceptable dimensional accuracy and stability, below 5%.…”

3D‐Printing to Mitigate COVID‐19 Pandemic

“…[212] Another study also observed that a combination of both the methods (3D-printing and injection molding), especially reduces the cost and enhances the production speed of printing. [40,213,214] Other findings also note that 3D-printing reduces the shipping and manufacturing costs and around 70% of prototyping costs involved in traditional manufacturing. [215] The digitallyenabled mechanisms of 3D printing techniques cut shorts a number of these processes, and thereby can be accessed at a cheap rate from any part of the world.…”

“…[ 212 ] Another study also observed that a combination of both the methods (3D‐printing and injection molding), especially reduces the cost and enhances the production speed of printing. [ 40,213,214 ]…”

Additive manufacturing for COVID-19: Devices, materials, prospects, and challenges

“…A most common way that these groups have contributed include activities in producing hundreds and even thousands of PPEs (face shields, masks, and venture valves). [48,95,96] (see Supplementary Material).…”

“…Our group recently published a study regarding the possibility of combining AM (3D printing) and formative manufacturing (injection molding). [95,96] The cost and lead time for tooling/ mold fabrication will be significantly reduced when these two processes are combined. Therefore, the 3D-printed tool or die becomes a multiplier.…”