An analysis of Digital ABS as a rapid tooling material for polymer injection moulding

Volpato, Neri; Solis, Daphene Marques; Costa, Carlos Alberto

doi:10.1504/ijmpt.2016.073616

Cited by 30 publications

(26 citation statements)

References 5 publications

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“…Two types of materials were used in this study: VeroClear ( T g : 52–54 °C) and Digital‐ABS ( T g : 47–53 °C). In particular, Digital ABS has been widely used for 3D printing of mold inserts due to its long tool life (80 or more shots with elastomeric plastics) and suitability for molding complex geometries or molding with higher temperature thermoplastics . In nanoimprinting process, the surface to be imprinted is referred to as the substrate.…”

Section: Resultsmentioning

confidence: 99%

Nanostructured Free‐Form Objects via a Synergy of 3D Printing and Thermal Nanoimprinting

Lee

Low

2018

Global Challenges

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High‐resolution surface patterning has garnered interests as a nonchemical‐based surface engineering approach for creating functional surfaces. Applications in consumer products, parts for transportation vehicles, optics, and biomedical technologies demand topographic patterning on 3D net shape objects. Through a hybrid approach, high‐resolution surface texture is incorporated onto 3D‐printed polymers via direct thermal nanoimprinting process. The synergy of geometry design freedom in 3D printing and the high spatial resolution in nanoimprinting is demonstrated to be a versatile fabrication of high‐fidelity surface pattern (from 2 µm to 200 nm resolution) on convex, concave semicylindrical, and hemispherical objects spanning a range of surface curvatures. The novel hybrid fabrication is further extended to achieve a high‐resolution curved mold insert for rapid prototyping via injection molding. The versatility of the fabrication strategies reported here not only provides a post‐3D printing process that enhances the surface properties of 3D‐printed objects but also opens a new pathway to enable future study on the effects of combining microscale and nanoscale surface texture with macroscopic curvature. Both have been known, individually, as an effective approach to tune surface functionalities.

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Section: Resultsmentioning

confidence: 99%

Nanostructured Free‐Form Objects via a Synergy of 3D Printing and Thermal Nanoimprinting

Lee

Low

2018

Global Challenges

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“…1a), and Izod impact strength with specimens following ASTM D256, were performed. The impact test specimens (measuring 63.5 × 12.7 × 3.2 mm) were extracted from the geometry of the bending specimens (ASTM D790), which were used in another work [10]. The specimens were injected in a zinc alloy prototype tooling, known commercially as zamak-8 with a thermal conductivity of 114.7 W/mK [11].…”

Section: Methodsmentioning

confidence: 99%

“…The specimens were injected in a Haitian HTF-58X molding machine. Table 1 shows the main injection parameters used to obtain the PP moldings in the steel and zamak-8 molds which were defined based on previous experience with these molds [10]. The mold temperature (T m ) and the injection temperature (T i ) for the zamak-8 were set at three different levels, resulting in a complete factorial (3 2 ) with nine experiments.…”

Section: Methodsmentioning

confidence: 99%

Adjusting process parameters in zamak-8 prototype tooling to obtain functional prototypes in PP

Volpato

Junkes

2020

J Braz. Soc. Mech. Sci. Eng.

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Prototype tooling is an option to obtain functional prototypes, or even final parts, in low-scale injection molding. In order to reduce the manufacturing time and cost of this type of tooling, alternative materials, such as zinc alloys, can be employed. However, the mold material and injection parameters can influence molding crystallinity and mechanical properties. The zinc alloy known as zamak-8 has not been explored much for this application. The objective of this work is to study the influence of this mold material on the properties of polypropylene (PP) when varying the mold (T m) and injection (T i) temperatures. Then, based on that, to develop some regression models to help obtain PP moldings in the zamak-8 mold with similar characteristics to those injected in a steel mold, which was used as a reference, the characterization techniques used were tensile and impact tests, and differential scanning calorimetry as well, to measure crystallinity. The results showed that zamak-8 prototype tooling only has a significant influence on the impact strength of the injected PP. The regression models showed that to obtain injected prototypes with mechanical and crystalline properties close to a production part in this specific study, T m should be set at around 40 °C and T i at 225 °C. In general, this indicates that zamak-8 can be used to obtain functional prototypes in PP with similar properties to the production parts.

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“…Polymer parts produced by AM has been proved directly applicable as mold inserts. For example as reported in [15] and [16]. Inserts manufactured from carbon fiber reinforced photopolymer has withstood up to 2500 injection molding cycles for polyethylene before noticeable mold deterioration was observed [17].…”

Section: Introductionmentioning

confidence: 94%

A Soft Tooling process chain employing Additive Manufacturing for injection molding of a 3D component with micro pillars

Zhang

Pedersen

Gøtje

et al. 2017

Journal of Manufacturing Processes

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The purpose of the research presented in this paper is to investigate the capability of a soft tooling process chain employing Additive Manufacturing (AM) for preproduction of an insert with micro features by injection moulding. The Soft Tooling insert was manufactured in a high temperature photopolymer by Digital Light Processing (vat photopolymerization). The mold cavity was formed by two insert halves, by design; both inserts have four angled tines, with micro holes (Ø200 µm, 200 µm deep) on the surface. Injection molding with polyethylene was used with the soft tool inserts to manufacture the final production components. The diameter and height of the pillars that were replicated on the molded components were characterized by means of a 3D profilometer. The influence of the injection molding parameters on the replication was evaluated using a 2-levels DOE of three factors. The uniformity of the pillars are also evaluated regarding the diameter and height.

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An analysis of Digital ABS as a rapid tooling material for polymer injection moulding

Cited by 30 publications

References 5 publications

Nanostructured Free‐Form Objects via a Synergy of 3D Printing and Thermal Nanoimprinting

Nanostructured Free‐Form Objects via a Synergy of 3D Printing and Thermal Nanoimprinting

Adjusting process parameters in zamak-8 prototype tooling to obtain functional prototypes in PP

A Soft Tooling process chain employing Additive Manufacturing for injection molding of a 3D component with micro pillars

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