Influence of thermo-mechanical loads on the lifetime of plastic inserts for injection moulds produced via additive manufacturing

Bogaerts, Lars; Faes, Matthias; Bergen, J. A. van; Cloots, J.; Vasiliauskaite, Eglé; Vogeler, Frederik; Moens, David

doi:10.1016/j.procir.2021.01.061

Cited by 9 publications

(5 citation statements)

References 9 publications

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“…Hence, it is of interest to study how the TCR and the R M impact on the t c for the polymer-based mold. The modification of parameters involving substantial reductions in coolant temperature and extensions of the cycle time is common in PIs for achieving desired ejection temperatures [1][2][3]18]. In light of the detrimental effects of high mold temperatures and hot spots on insert durability [3,17], a coolant temperature of T c = 10 • C is adopted for the numerical simulations henceforth.…”

Section: Sensitivity and Order-of-magnitude Analysismentioning

confidence: 99%

“…Bogaerts et al [3] conducted a similar comparative study and found that temperature concentrations and large variations were the primary cause of insert failures. Additionally, numerical models were shown to be useful in designing plastic inserts and optimizing process parameters to improve thermal performance.…”

Section: Introductionmentioning

confidence: 97%

“…Specifically, they exhibit thermal diffusivity and elasticity modulus on the order of 100 times lower, and a thermal expansion coefficient approximately 10 times higher, making the cooling of the part in a reasonable time without mold failure a challenge. Indeed, the unpredictability of the tool life of such polymer-based inserts is the main concern of mold manufacturers nowadays, and the reason of many ongoing research [1][2][3][4].…”

Section: Introductionmentioning

confidence: 99%

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A numerical framework for three-dimensional optimization of cooling channels in thermoplastic printed molds

Storti,

Sobotka

2024

Applied Thermal Engineering

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Section: Sensitivity and Order-of-magnitude Analysismentioning

confidence: 99%

Section: Introductionmentioning

confidence: 97%

Section: Introductionmentioning

confidence: 99%

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A numerical framework for three-dimensional optimization of cooling channels in thermoplastic printed molds

Storti,

Sobotka

2024

Applied Thermal Engineering

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“…3a) or centering pins outside the cavity or by a special course of the parting line, curved curves being preferred [14]. The cavities should be designed as symmetrically as possible in terms of length, width, height and geometric structures [15]. In order to reduce manufacturing times, the cross-sections of the mold insert halves should be optimized at points which do not support the cavity or are carriers of the clamping force [8].…”

Section: Symmetry and Separation Planementioning

confidence: 99%

Review and Development of Design Guidelines for Additive Tooling of Injection Molds Using PolyJet Modelling

Junk,

Schrock,

Schmieder

2023

Springer Tracts in Additive Manufacturing

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Due to globalization and the resulting increase in competition on the market, products must be produced more and more cheaply, especially in series production, because buyers expect new variants or even completely new products in ever shorter cycles. Injection molding is the most important production process for manufacturing plastic components in large quantities. However, the conventional production of a mold is extremely time-consuming and costly, which creates a contradiction to the fast pace of the market. Additive tooling is an area of application of additive manufacturing, which in the field of injection molding is preferably used for the prototype production of mold inserts. This allows injection molding tools to be produced faster and more cheaply than through the subtractive manufacturing of metal tools. Material Jetting processes using polymers (MJT-UV/P), also called Polyjet Modeling (PJM), have a great potential for use in additive tooling. Due to the poorer mechanical and thermal properties compared to conventional mold insert materials, e.g. steel or aluminum, the previously used design principles cannot be applied. Accordingly, new design guidelines are necessary, which are developed in this paper. The necessary information is obtained with the help of a systematic literature research. The design guidelines are mapped in a uniform design guide, which is structured according to the design process of injection molds. The guidelines do not only refer to the constructive design of the injection mold or the polymer mold insert, but to the entire design process and describe the four phases of planning, conception, development and realization. Particular attention is paid to the special geometric designs of a polymer mold insert and the thermomechanical properties of the mold insert materials. As a result, design guidelines are available that are adapted to the special requirements of additive tooling of molds inserts made of plastics for injection molding.

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“…Notably, Stratasys defined PolyJet Digital acrylonitrile butadiene styrene (ABS) polymer mould inserts that are economically interesting in case an amount of 5-100 parts is necessary [18]. Failure of Digital ABS mould inserts is mainly initiated by the effect of a higher overall shear rate due to the claimed absence of a skin layer near the cavity walls [19]. Another method which demonstrated the usefulness of AM is casting tools which subsequently can be used to produce moulds [20].…”

Section: Introductionmentioning

confidence: 99%

Optimising open and closed cooling time for hybrid injection moulding of polypropylene with polyamide inserts from multi jet fusion

Fernandez

Ryse

Cavicchiolo

et al. 2020

Plastics, Rubber and Composites

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To reduce the lead time and costs for developing short run production injection moulding tools the potential of additive manufactured mould inserts is investigated. These hybrid moulds are compared to conventional steel-based moulds, considering mechanical and thermal differences. For part production and insert material, respectively polypropylene and polyamide12 manufactured by Multi Jet Fusion (MJF) are chosen. Moldex3D simulation results show that lower clamping forces and injection pressures are sufficient upon using MJF inserts due to a 20 times lower thermal diffusivity compared to conventional steel, resulting in thinner skin layers and increased solidification times. Practical injection moulding parameters have been optimized by reducing the cooling time with 75 seconds (60%) using forced convectional cooling at 15 °C. Core and cavity inserts show a deviating cooling behaviour linked to the higher amount of insert material and presence of steel. The wear of the mould inserts is minor after producing 360 parts. .

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Influence of thermo-mechanical loads on the lifetime of plastic inserts for injection moulds produced via additive manufacturing

Cited by 9 publications

References 9 publications

A numerical framework for three-dimensional optimization of cooling channels in thermoplastic printed molds

A numerical framework for three-dimensional optimization of cooling channels in thermoplastic printed molds

Review and Development of Design Guidelines for Additive Tooling of Injection Molds Using PolyJet Modelling

Optimising open and closed cooling time for hybrid injection moulding of polypropylene with polyamide inserts from multi jet fusion

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