Micro Injection Molding of Thin Cavities Using Stereolithography for Mold Fabrication

Surace, Rossella; Basile, Vito; Bellantone, Vincenzo; Modica, Francesco; Fassi, Irene

doi:10.3390/polym13111848

Cited by 21 publications

(15 citation statements)

References 25 publications

(26 reference statements)

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“…In [15], a thin cavity mould was manufactured via SLA by using two Formlabs resin: standard Grey Resin and High Temperature Resin. The samples were post-processed with UV exposure (60 min at 60 • C for Grey, 120 min for 80 • C for High Temperature).…”

Section: Literature Review On Curing Effects For Sla Resinsmentioning

confidence: 99%

Effects of Curing on Photosensitive Resins in SLA Additive Manufacturing

Riccio¹,

Civera²,

Ruiz³

et al. 2021

Applied Mechanics

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Different mechanical properties characterise the materials of 3D printed components, depending on the specific additive manufacturing (AM) process, its parameters, and the post-treatment adopted. Specifically, stereolithography (SLA) uses a photopolymerisation technique that creates solid components through selective solidification. In this study, 72 specimens were 3D printed using 12 commercial-grade methacrylate resins and tested under uniaxial tensile loads. The resin specimens were evaluated before and after curing. The recommended cure temperature and time were followed for all materials. The stress-strain curves measured during the testing campaign were evaluated in terms of maximum tensile strength, Young’s modulus, ductility, resilience, and toughness. The results reveal that the curing process increases the material stiffness and resistance to tensile loads. However, it was found that the curing process generally reduces the plasticity of the resins, causing a more or less marked brittle behaviour. This represents a potential limitation to the use of SLA 3D printing for structural elements which require some plasticity to avoid dangerous sudden failures.

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Section: Literature Review On Curing Effects For Sla Resinsmentioning

confidence: 99%

Effects of Curing on Photosensitive Resins in SLA Additive Manufacturing

Riccio¹,

Civera²,

Ruiz³

et al. 2021

Applied Mechanics

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“…Finally, the mold is opened for demolding of the plastic part to obtain the molded part. During the molding cycle of PIM, the quality of the molded part is influenced by molding parameters [4], mold design [5], product design [6], and material [7], as summarized in Fig. 1.…”

Section: Introductionmentioning

confidence: 99%

A research method to improve the quality of box-type thin-walled parts by combining parameter optimization and i nverse-deformation design

Zhai

Chang²,

Li³

et al. 2022

Preprint

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In this paper, a five-part study on the molding quality of box-type thin-walled injection molded parts with volume shrinkage and warpage deformation was conducted. In the first part, the molding parameters: filling time, plastic temperature, mold temperature (C), holding time (D), maximum holding pressure (E), and cooling time (F) were selected, and a six-factor, five-level L25 (5 6 ) orthogonal experimental design (OED) was designed. Then, the optimal combination of molding parameters was optimized by using gray correlation (GC) theory analysis. In the second part, the six molding parameters from the first part were further optimized based on the Box Behnken Design (BBD) response surface method (RSM) and BP neural network (BPNN) training, and the results showed that the fitted regression model after BPNN training had a smaller prediction error. In the third part, the regression models fitted with BBD and BPNN-BBD are further optimized globally. The optimization search method uses the NSGA-II genetic optimization algorithm. And comparing the above four optimization methods found that BPNN-BBD-NSGA-II prediction error < BPNN-BBD prediction error < BBD-NSGA-II prediction error < BBD prediction error. The fourth part is based on the anti-deformation design (ADD) theory. The NX/Moldex3D global optimization platform is created to finally almost completely eliminate warpage deformation of box-type thin-walled injection molded parts. In the last part, a trial mold verification analysis was performed, and the molding quality data was obtained by using optical scanning instruments, and the GOM software was used to compare and analyze the deviation values of each appearance surface and the flatness values.

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“…The application of 3D-printing technology in the case of unit production allows the omission the time-consuming and often costly stage of producing the necessary equipment [7], which can be seen in the case of the plastics industry. It is becoming more and more common to perform short, pilot production series (several-over a dozen elements) with the use of replaceable, 3D-printed inserts for injection molds [8] made of a special material resistant to high temperature [9,10]. The leader in the field of application of 3D-printed injection mold elements is Stratasys Ltd., which uses its patented PolyJet photopolymer 3D-printing technology (minimal layer thickness is 16 µm).…”

Section: Introductionmentioning

confidence: 99%

Non-Contact Multiscale Analysis of a DPP 3D-Printed Injection Die for Investment Casting

et al. 2021

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The investment casting method supported with 3D-printing technology, allows the production of unit castings or prototypes with properties most similar to those of final products. Due to the complexity of the process, it is very important to control the dimensions in the initial stages of the process. This paper presents a comparison of non-contact measurement systems applied for testing of photopolymer 3D-printed injection die used in investment casting. Due to the required high quality of the surface parameters, the authors decided to use the DPP (Daylight Polymer Printing) 3D-printing technology to produce an analyzed injection die. The X-ray CT, Structured blue-light scanner and focus variation microscope measurement techniques were used to avoid any additional damages to the injection die that may arise during the measurement. The main objective of the research was to analyze the possibility of using non-contact measurement systems as a tool for analyzing the quality of the surface of a 3D-printed injection die. Dimensional accuracy analysis, form and position deviations, defect detection, and comparison with a CAD model were carried out.

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Micro Injection Molding of Thin Cavities Using Stereolithography for Mold Fabrication

Cited by 21 publications

References 25 publications

Effects of Curing on Photosensitive Resins in SLA Additive Manufacturing

Effects of Curing on Photosensitive Resins in SLA Additive Manufacturing

A research method to improve the quality of box-type thin-walled parts by combining parameter optimization and i nverse-deformation design

Non-Contact Multiscale Analysis of a DPP 3D-Printed Injection Die for Investment Casting

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