Combination of 3D printing and injection molding: Overmolding and overprinting

Boros, Róbert; Rajamani, Praveen Kannan; Kovács, József

doi:10.3144/expresspolymlett.2019.77

Cited by 45 publications

(33 citation statements)

References 28 publications

(28 reference statements)

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“…Optimising the fibre alignment within each layer to alternating orientation from point to point has not been adopted, albeit due to the nonavailability of necessary commercial tools. Moreover, MEX composite parts are fairly lucrative in terms of overall economics but have poor mechanical and thermal material characteristics [ 12 , 13 ].…”

Section: Introductionmentioning

confidence: 99%

Additively Manufactured Composite Lug with Continuous Carbon Fibre Steering Based on Finite Element Analysis

2022

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In this study, the influence of curvilinear fibre reinforcement on the load-carrying capacity of additively manufactured continuous carbon fibre reinforced necked double shear lugs was investigated. A curvilinear fibre placement is descriptive of layers in extrusion-based continuous-fibre-reinforced additive manufacturing with carbon fibres aligned in the directions of principal stress. The alternating layered fibre trajectories follow the maximum and minimum principal stress directions due to axial tension loading derived from two-dimensional finite element analysis (FEA). The digital image correlation was utilised to monitor the strain distribution during the application of tensile load. The 2D FEA data and the tensile test results obtained were comparable, the part strength and the linear approximation of stiffness data variability were minimal and well within the acceptable range. Nondestructive fractography was performed by utilising computed tomography (CT) to analyse the fractured regions of the tensile-tested lug. The CT scanned images aided in deducing the failure phenomenon in layered lugs; process-induced voids and fibre layup undulation were identified as the cause for lug failure.

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Section: Introductionmentioning

confidence: 99%

Additively Manufactured Composite Lug with Continuous Carbon Fibre Steering Based on Finite Element Analysis

2022

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“…However, AM’s bottleneck is the production rate in the long run, which is three to four orders of magnitude slower than that of injection molding [ 6 ]. A combination of a relatively high production rate and customized production can be achieved with hybrid technologies, where several plastic processing techniques are combined to manufacture a single part [ 7 , 8 , 9 , 10 ].…”

Section: Introductionmentioning

confidence: 99%

Personalized Mass Production by Hybridization of Additive Manufacturing and Injection Molding

2021

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The new trend in the composites industry, as dictated by Industry 4.0, is the personalization of mass production to match every customer’s individual needs. Such synergy can be achieved when several traditional manufacturing techniques are combined within the production of a single part. One of the most promising combinations is additive manufacturing (AM) with injection molding. AM offers higher production freedom in comparison with traditional techniques. As a result, even very sophisticated geometries can be manufactured by AM at a reasonable price. The bottleneck of AM is the production rate, which is several orders of magnitude slower than that of traditional plastic mass production technologies. On the other hand, injection molding is a manufacturing technique for high-volume production with little possibility of customization. The customization of injection-molded parts is usually very expensive and time-consuming. In this research, we offered a solution for the individualization of mass production, which includes 3D printing a baseplate with the subsequent overmolding of a rib element on it. We examined the bonding between the additive-manufactured component and the injection-molded component. As bonding strength between the coupled elements is significantly lower than the strength of the material, we proposed five strategies to improve bonding strength. The strategies are optimizing the printing parameters to obtain high surface roughness, creating an infill density in fused filament fabrication (FFF) parts, creating local infill density, creating microstructures, and incorporating fibers into the bonding area. We observed that the two most effective methods to increase bonding strength are the creation of local infill density and the creation of a microstructure at the contact area of FFF-printed and injection-molded elements. This increase was attributed to the porous structures that both methods created. The melt during injection molding flowed into these pores and formed micro-mechanical interlocking.

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“…This method allows engineers to generate products with three‐dimensional complex geometries. [ 30 ] The high‐pressure shear flow in the closed cavity has a profound impact on the structure and properties of polymers. The complex injection molding process has attracted widespread attention in academia and industry.…”

Section: Introductionmentioning

confidence: 99%

Effect of injection molding on structure and properties of poly(styrene‐ethylene‐butylene‐styrene) and its nanocomposite with functionalized montmorillonite

Xiong

et al. 2020

J of Applied Polymer Sci

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In this paper, the effects of injection molding on structure and properties of poly(styrene-ethylene-butylene-styrene) (SEBS) and its nanocomposite with a functionalized montmorillonite (FMMT) were illustrated by comparison with the results of hot pressing. The injection-molded SEBS and its FMMT nanocomposite have a skin-core morphology with FMMT platelets more preferentially aligned along the sample plane, while hot-pressed samples not. The injection-molded samples also have a dense structure, and a less extent of microphase separation. In the injection molding process, the high shear flow coupled with solidification in presence of temperature gradient and high pressure in the closed cavity greatly affect the morphology and structure of the SEBS and its nanocomposites. The results also indicate attractive interaction between the soft segments of SEBS and the long alkyl silane chain grafted to FMMT, which allows FMMT to form a macroscopic network structure after the high-speed and high-pressure injection molding. The SEBS/FMMTinjected nanocomposite have the highest tensile strength and the best corrosion resistance, which can be attributed to the dense skin-core structure, stronger SEBS/FMMT interaction and the preferentially aligned FMMT platelets.

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Combination of 3D printing and injection molding: Overmolding and overprinting

Cited by 45 publications

References 28 publications

Additively Manufactured Composite Lug with Continuous Carbon Fibre Steering Based on Finite Element Analysis

Additively Manufactured Composite Lug with Continuous Carbon Fibre Steering Based on Finite Element Analysis

Personalized Mass Production by Hybridization of Additive Manufacturing and Injection Molding

Effect of injection molding on structure and properties of poly(styrene‐ethylene‐butylene‐styrene) and its nanocomposite with functionalized montmorillonite

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