A cost-effective approach for rapid manufacturing wax injection molds with complex geometrical shapes of cooling channels

Kuo, Chil-Chyuan; Xu, Wei-Cong

doi:10.1007/s00170-016-9886-4

Cited by 20 publications

(9 citation statements)

References 25 publications

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“…In addition, an injection mold fabricated by RTT had some distinct advantages, including mold size, interior quality of the CCCs, production costs, and post-processing operations compared with injection mold fabricated by metal AM, such as selective laser sintering (SLS), selective laser melting (SLM), and diffusion bonding (DB) technologies. A low-cost wax injection mold with high cooling efficiency was developed [ 16 , 17 ]. A hot embossing stamp with CCCs for microreplication was developed [ 18 ].…”

Section: Introductionmentioning

confidence: 99%

Rapid Development of an Injection Mold with High Cooling Performance Using Molding Simulation and Rapid Tooling Technology

et al. 2021

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Rapid tooling technology (RTT) provides an alternative approach to quickly provide wax injection molds for the required products since it can reduce the time to market compared with conventional machining approaches. Removing conformal cooling channels (CCCs) is the key technology for manufacturing injection mold fabricated by rapid tooling technology. In this study, three different kinds of materials were used to fabricate CCCs embedded in the injection mold. This work explores a technology for rapid development of injection mold with high cooling performance. It was found that wax is the most suitable material for making CCCs. An innovative method for fabricating a large intermediary mold with both high load and supporting capacities for manufacturing a large rapid tooling using polyurethane foam was demonstrated. A trend equation for predicting the usage amount of polyurethane foam was proposed. The production cost savings of about 50% can be obtained. An optimum conformal cooling channel design obtained by simulation is proposed. Three injection molds with different cooling channels for injection molding were fabricated by RTT. Reductions in the cooling time by about 89% was obtained. The variation of the results between the experiment and the simulation was investigated and analyzed.

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Section: Introductionmentioning

confidence: 99%

Rapid Development of an Injection Mold with High Cooling Performance Using Molding Simulation and Rapid Tooling Technology

et al. 2021

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“…Thus, further works are required to optimize the layout of the CCCs using the simulation software. The mechanical properties of SRM are inferior to that fabricated by aluminum (Al)-filled epoxy resins [ 58 , 59 , 60 , 61 ]. Therefore, the Al-filled epoxy resins can be used to make an injection molding tool with CCC for batch production of wax patterns.…”

Section: Resultsmentioning

confidence: 99%

Improving Cooling Performance of Injection Molding Tool with Conformal Cooling Channel by Adding Hybrid Fillers

Kuo

2021

Polymers

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Silicone rubber mold (SRM) is capable of reducing the cost and time in a new product development phase and has many applications for the pilot runs. Unfortunately, the SRM after injection molding has a poor cooling efficiency due to its low thermal conductivity. To improve the cooling efficiency, the thermal conductivity of the SRM was improved by adding fillers into the SRM. An optimal recipe for fabricating a high cooling efficiency low-pressure injection mold with conformal cooling channel fabricated by fused deposition modeling technology was proposed and implemented. This study proposes a recipe combining 52.6 wt.% aluminum powder, 5.3 wt.% graphite powder, and 42.1 wt.% liquid silicon rubber can be used to make SRM with excellent cooling efficiency. The price–performance ratio of this SRM made by the proposed recipe is around 55. The thermal conductivity of the SRM made by the proposed recipe can be increased by up to 77.6% compared with convention SRM. In addition, the actual cooling time of the injection molded product can be shortened up to 69.1% compared with the conventional SRM. The actual cooling time obtained by the experiment is in good agreement with the simulation results with the relative error rate about 20%.

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“…Aluminium filled epoxy resin mould used for the development of investment casting wax pattern requires high cycle time due to its lower thermal conductivity. Hence, an aluminium filled epoxy resin mould with conformal cooling channels (made by FDM) has been developed by Kuo et al (2017). Thin shell cooling channels prepared from ABS material was incorporated into the aluminium filled epoxy resin mould during its preparation, and the integrated conformal circuit was removed from the final mould using acetone flushing.…”

Section: Applicationsmentioning

confidence: 99%

A review on advancements in applications of fused deposition modelling process

Sathies

Senthil

Anoop

2020

RPJ

102

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Purpose Fabrication of customized products in low volume through conventional manufacturing incurs a high cost, longer processing time and huge material waste. Hence, the concept of additive manufacturing (AM) comes into existence and fused deposition modelling (FDM), is at the forefront of researches related to polymer-based additive manufacturing. The purpose of this paper is to summarize the research works carried on the applications of FDM. Design/methodology/approach In the present paper, an extensive review has been performed related to major application areas (such as a sensor, shielding, scaffolding, drug delivery devices, microfluidic devices, rapid tooling, four-dimensional printing, automotive and aerospace, prosthetics and orthosis, fashion and architecture) where FDM has been tested. Finally, a roadmap for future research work in the FDM application has been discussed. As an example for future research scope, a case study on the usage of FDM printed ABS-carbon black composite for solvent sensing is demonstrated. Findings The printability of composite filament through FDM enhanced its application range. Sensors developed using FDM incurs a low cost and produces a result comparable to those conventional techniques. EMI shielding manufactured by FDM is light and non-oxidative. Biodegradable and biocompatible scaffolds of complex shapes are possible to manufacture by FDM. Further, FDM enables the fabrication of on-demand and customized prosthetics and orthosis. Tooling time and cost involved in the manufacturing of low volume customized products are reduced by FDM based rapid tooling technique. Results of the solvent sensing case study indicate that three-dimensional printed conductive polymer composites can sense different solvents. The sensors with a lower thickness (0.6 mm) exhibit better sensitivity. Originality/value This paper outlines the capabilities of FDM and provides information to the user about the different applications possible with FDM.

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A cost-effective approach for rapid manufacturing wax injection molds with complex geometrical shapes of cooling channels

Cited by 20 publications

References 25 publications

Rapid Development of an Injection Mold with High Cooling Performance Using Molding Simulation and Rapid Tooling Technology

Rapid Development of an Injection Mold with High Cooling Performance Using Molding Simulation and Rapid Tooling Technology

Improving Cooling Performance of Injection Molding Tool with Conformal Cooling Channel by Adding Hybrid Fillers

A review on advancements in applications of fused deposition modelling process

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