Hybrid manufacturing of mixed‐material bilayer parts via injection molding and material extrusion three‐dimensional printing

Abstract

In this paper, a hybrid manufacturing method combining the advantages of injection molding (IM) in terms of manufacturing efficiency and high precision with those of three-dimensional printing (3DP) in terms of minimum waste and a high degree of freedom is described to produce mixed-material bilayer tensile specimens. 3DP was first utilized to fabricate polylactic acid substrates with four varied geometries and two infill densities and an overmolding technique was employed to finish the manufacture using acrylonitrile butadiene styrene under two IM pressure. analysis of variance and scanning electron microscopy (SEM) were used to investigate the tensile properties and microstructures of the samples. The results showed that a greater tensile performance could be found in those specimens with greater infill density.Lower-pressure overmolded specimens performed better than those with higher IM pressure. In addition, female joints outperformed male joints in the tensile performances of finished specimens. This study optimized the parameters for this hybrid manufacturing process for building mixed-material parts and has potential applications in manufacturing, particularly manufacturing as a service.

Rheological Behaviour of ABS/Metal Composites with Improved Thermal Conductivity for Additive Manufacturing

“…From the point of view of the material, the acrylonitrile-butadiene-styrene copolymer (ABS) is known for its excellent mechanical and impact strengths, dimensional stability, good chemical resistance, low water absorption and high filling capacity, arising as a popular thermoplastic material of choice for FDM applications as it offers satisfactory processability and a relatively low melting temperature [5,[26][27][28][29]. The manufacturing of ABS composites through additive manufacturing (AM) techniques, such as FDM, has been demonstrated [30][31][32][33][34], and melt flow index (MFI) analysis has been a popular testing choice to evaluate the flow behaviour trends of ABS composites developed for 3D printing [35][36][37][38][39][40][41].…”