A new hybrid process combining rapid tooling and machining to manufacture an injection mold with micro features

Kuo, Chil-Chyuan; Lin, Bo-Han; Luo, Zheng-Ting

doi:10.1007/s00170-021-08529-7

Cited by 3 publications

(3 citation statements)

References 24 publications

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“…, 2021; Kuo and Li, 2017). AM challenges conventional machining processes in delivering mould or cavity features in terms of cost and speed by using its additive nature (Kuo et al. , 2022).…”

Section: Introductionmentioning

confidence: 99%

“…This resulted in an increasing interest in AM tooling, or "rapid tooling", made from polymers that can be an alternative to accelerate product and process development for hot embossing, injection moulding and forming processes (Gülçür et al, 2023a;Gohn et al, 2022;Kuo et al, 2021;Kuo and Li, 2017). AM challenges conventional machining processes in delivering mould or cavity features in terms of cost and speed by using its additive nature (Kuo et al, 2022). Improvements in three-dimensional (3D) printers or AM machines also push the minimum feature size (or resolution) to levels down to single-digit microns (Ge et al, 2020;Guven et al, 2022;Ladner et al, 2019).…”

Section: Introductionmentioning

confidence: 99%

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Investigating demoulding characteristics of material jetted rapid mould inserts for microinjection moulding using inline monitoring and surface metrology

Gülçür,

Isakov,

Charmet

et al. 2024

RPJ

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Purpose This study aims to investigate the demoulding characteristics of material-jetted rapid mould inserts having different surface textures for micro-injection moulding using in-line measurements and surface metrology. Design/methodology/approach Material-jetted inserts with the negative cavity of a circular test product were fabricated using different surface finishes and printing configurations, including glossy, matte and vertical settings. In-line measurements included the recording of demoulding forces at 10 kHz, which was necessary to capture the highly-dynamic characteristics. A robust data processing algorithm was used to extract reliable demoulding energies per moulding run. Thermal imaging captured surface temperatures on the inserts after demoulding. Off-line measurements, including focus variation microscopy and scanning electron microscopy, compared surface textures after a total of 60 moulding runs. Findings A framework for capturing demoulding energies from material-jetted rapid tools was demonstrated and compared to the literature. Glossy surfaces resulted in significantly reduced demoulding forces compared to the industry standard steel moulds in the literature and their material-jetted counterparts. Minimal changes in the surface textures of the material-jetted inserts were found, which could potentially permit their prolonged usage. Significant correlations between surface temperatures and demoulding energies were demonstrated. Originality/value The research presented here addresses the very topical issue of demoulding characteristics of soft, rapid tools, which affect the quality of prototyped products and tool durability. This was done using state-of-the-art, high-speed sensing technologies in conjunction with surface metrology and their durability for the first time in the literature.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Investigating demoulding characteristics of material jetted rapid mould inserts for microinjection moulding using inline monitoring and surface metrology

Gülçür,

Isakov,

Charmet

et al. 2024

RPJ

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“…Today, the main application of RT in conventional production processes is in casting, where it is used in complex-shape and net-shape manufacturing [7,8]. It is also used in injection moulding, to increase process flexibility and reconfigurability [9,10], and in forming, to reduce process costs and production times [11,12]. To increase awareness of the application of RT in conventional processes, the present study focused on the use of carbon-reinforced polymers to produce tooling for deep drawing applications with fused filament fabrication (FFF) technology.…”

Section: Introductionmentioning

confidence: 99%

Deep Drawing of AISI 304 Blanks with Polymer Punches Produced by Additive Manufacturing: Effects of Process Scalability

Giorleo

2022

Applied Sciences

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Rapid tooling is a methodology which aims to integrate additive manufacturing into the production of tools to be used in casting, forming or machining processes. In forming, rapid tooling is applied in the production of metallic or plastic tools that guarantee good performance in small- and medium-sized batch production. However, most punches tested to date have dimensions measured in millimeters and are therefore unsuitable for typical real-world industrial processes. In this study, the performance of plastic punches with geometries designed for industrial application was investigated. A deep drawing process involving AISI 304 blanks was created for the manufacturing of cups. Experimental and numerical analyses were conducted to measure the quality of the cups produced and the behaviour of the punches involved. The results indicate that when punch dimensions increase, a more precise cup geometry is produced (99% of drawing depth, 98% of cup precision on the fillet radius, and roundness error equal to 0.53%).

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Additively manufactured cure tools for composites manufacture

Valentine

Radhakrishnan

Maes

et al. 2023

Int J Adv Manuf Technol

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This research presents a novel framework for the design of additively manufactured (AM) composite tooling for the manufacture of carbon fibre-reinforced plastic composites. Through the rigorous design and manufacture of 30 unique AM tools, the viability of a design for AM framework was evaluated through measuring the performance with respect to geometrical accuracy and thermal responsiveness, and simulating the tool specific stiffness. The AM components consisted of a thin layup facesheet, stiffened by a low density lattice geometry. These tools were successfully used to layup and cure small composite components. The tooling was highly thermally responsive, reaching above 93% of the applied oven heating rate and up to 17% faster heating rates compared to similar mass monolithic tools. The results indicate that thermal overshoot has a greater dependence on the lattice density while the heating rate was more sensitive to the facesheet thickness. Lattice densities of as little as 5% were manufactured and the best overall geometry was a graded gyroid lattice with thicker walls near the surface and thinner walls at the base, attached to a 0.7 mm thick facesheet. The outputs from this research can provide a new route to the design and manufacture of mould tools, which could have significant impacts in the composites sector with new, lighter, more energy efficient tooling.

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A new hybrid process combining rapid tooling and machining to manufacture an injection mold with micro features

Cited by 3 publications

References 24 publications

Investigating demoulding characteristics of material jetted rapid mould inserts for microinjection moulding using inline monitoring and surface metrology

Investigating demoulding characteristics of material jetted rapid mould inserts for microinjection moulding using inline monitoring and surface metrology

Deep Drawing of AISI 304 Blanks with Polymer Punches Produced by Additive Manufacturing: Effects of Process Scalability

Additively manufactured cure tools for composites manufacture

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A new hybrid process combining rapid tooling and machining to manufacture an injection mold with micro features

Cited by 3 publications

References 24 publications

Investigating demoulding characteristics of material jetted rapid mould inserts for micro­injection moulding using in­line monitoring and surface metrology

Investigating demoulding characteristics of material jetted rapid mould inserts for micro­injection moulding using in­line monitoring and surface metrology

Deep Drawing of AISI 304 Blanks with Polymer Punches Produced by Additive Manufacturing: Effects of Process Scalability

Additively manufactured cure tools for composites manufacture

Contact Info

Product

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Investigating demoulding characteristics of material jetted rapid mould inserts for microinjection moulding using inline monitoring and surface metrology

Investigating demoulding characteristics of material jetted rapid mould inserts for microinjection moulding using inline monitoring and surface metrology