Opportunities and challenges of profile extrusion dies produced by additive manufacturing processes

Yesildag, Nafi; Hopmann, Christian; Windeck, Christian; Bremen, Sebastian; Wissenbach, Konrad; Merkt, Simon

doi:10.1063/1.5016712

Cited by 10 publications

(2 citation statements)

References 3 publications

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“…Due to the huge optical and haptic demands laid on thermoplastics profiles, typically, the whole flow channel of the profile extrusion die is finished after die production. A standard necessity is with this to reach a roughness Ra of a maximum of 1 μm in the flow region [28]. By contrast, the roughness of components fabricated by commercial SLM devices out of the steel or titanium has a value of at least 10 μm and even 20 μm (depends on the wall type and sloping angle), respectively [29][30][31][32][33].…”

Section: Discussionmentioning

confidence: 99%

Design and Selective Laser Melting Manufacturing of TPE Extrusion Die

Król

Musiorski²,

Pagáč

2020

SSP

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In presented work, extrusion die made by maraging steel used in TPE processing was optimised by means of flow dynamics of the final part. Maraging steel Ni-18 (M300) die were produced by Selective Laser Melting (SLM) using AM125 machine provided by Renishaw. The developed and manufactured extrusion die has not been processed by finishing the process, i.e. grinding, polishing or sandblasting. The tests were carried out using TPE industrial extrusion plant. Moreover, designed extrusion die to decrease weight and save the material; the design was hollow. The presented results indicate that the SLM technique is a promising method for the production in one production process the extrusion dies used in the TPE extrusion process with complex internal walls, with high accuracy, high speed and at low costs and own outlays. Moreover, this technique gives the constructors possibilities to design very complicated shapes of profiles with more than one of the working areas (bubbles) or design co-extrusion dies. Application of SLM technique allows to manufacture air ducts with pipe connectors to fasten an air, hence eliminating from the process expensive and time-consuming electrical discharge machining.

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Section: Discussionmentioning

confidence: 99%

Design and Selective Laser Melting Manufacturing of TPE Extrusion Die

Król

Musiorski²,

Pagáč

2020

SSP

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“…This approach eliminates material and energy waste. There are several studies investigated possibilities of tooling by means of metal AM [24,25]. AM have several exclusive features that make it even more efficient than conventional tooling processes.…”

Section: Figure 6 Conceptual Diagram Of Resource Circulation [20]mentioning

confidence: 99%

Investigation in Human Health, Environment and Safety Aspects of Additive Manufacturing (AM) Processes

Javidrad¹,

Larky²

2019

IJSEA

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Environmental impacts of every manufacturing procedure are a major consideration in every industry. These impacts include human health and safety and environmental burdens which are known as vital concerns in the industrial world. Before accepting any new process as a part of manufacturing procedure, a clear landscape from every aspect of that process should be provided. Additive manufacturing (AM) is growing from a prototyping method to the level of manufacturing functional products which require specific and accurate characterization information about every step of the whole production line. In this paper, attempts are made to address environmental impacts and safety considerations of metallic AM-based processes as well as their applicable solutions. AM processes are compared to conventional manufacturing methods from environmental aspects. Moreover, the benefits of metal AM as a fabricating and repairing method are presented. In conclusion, AM potential as a substitution or even complement for conventional manufacturing methods are discussed, where safety is considered vital.

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Performance evaluation of polymer-filled metal fused filament fabrication tooling for profile extrusion

Kain,

Parenti,

Annoni

et al. 2024

Int J Adv Manuf Technol

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The application of additive manufacturing (AM) for tooling in the mould and die industry brings a disruptive potential in process performance, design flexibility and product enhancements. Maturing of existing AM technologies and emerging technologies such as metal-fused filament fabrication (metal FFF) can further support the applicability of AM tooling in polymer profile extrusion. This study provides a complete characterization of metal FFF 17–4 PH stainless-steel die inserts and evaluates their applicability in a polymer extrusion process chain. The presented experimental assessment pivots on the metrological characterization of the produced inserts and the impact of the insert characteristics on the final extrudates’ product. Considering a conventionally manufactured benchmark insert, produced via subtractive methods (CNC machining and electrical discharge machining), comparable results for AM tools in terms of extrudates’ quality and process repeatability are presented. It was found that despite significant higher average surface parameters for AM insert tools (Sa = 2–9 µm vs. Sa = 0.3–0.9 µm for dies manufactured by machining), a much smaller difference was observed in the resulting quality of polymer extrudates’ product. The roughness generation effect of polymer profile extrusion based on the different dies’ internal surface roughness topography and the effect on extrudates product was evaluated. Three-dimensional average roughness Sa on acrylonitrile butadiene styrene extrudate surfaces obtained from conventionally machined dies was in the range of 0.3 µm. For extrudates obtained from additively manufactured dies, their Sa was in the rage of 0.5 µm (despite the much higher surface roughness of FFF dies compared to machined dies). The results confirm that with suitable extrudates’ product requirement, it is feasible to apply metal FFF as the selected manufacturing method for tooling in polymer profile extrusion.

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Opportunities and challenges of profile extrusion dies produced by additive manufacturing processes

Cited by 10 publications

References 3 publications

Design and Selective Laser Melting Manufacturing of TPE Extrusion Die

Design and Selective Laser Melting Manufacturing of TPE Extrusion Die

Investigation in Human Health, Environment and Safety Aspects of Additive Manufacturing (AM) Processes

Performance evaluation of polymer-filled metal fused filament fabrication tooling for profile extrusion

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