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Experimental investigation and thermo-mechanical modelling for tool life evaluation of photopolymer additively manufactured mould inserts in different injection moulding conditions
摘要： There is a growing interest for integrating additive manufacturing (AM) technology in different manufacturing processes such as injection moulding (IM) due to the possibility of achieving shorter manufacturing times and increased cost effectiveness. This paper evaluates IM inserts fabricated by the AM vat photopolymerisation method. The inserts are directly manufactured with a photopolymer material, integrated on an injection moulding tool and subsequently used for IM. Therefore, particular attention has to be paid in order to develop the soft tooling process chain and the IM experimental procedure as detailed in this study. Different combinations of IM parameters are investigated in this work in order to determine the influence of the various process settings on the inserts’ performance (lifetime, crack propagation, consistency of the mould surface features). The mould inserts were analysed by three-dimensional optical metrology and evaluated with regard to the different surface features that were affected by the IM process. A three-dimensional thermo-mechanical with phase change model for the analysis of the effects of the IM process on the additive manufactured tools was accomplished in the FE software COMSOL Multiphysics. The potential causes for the insert failure are identified both by means of the IM experiments and the numerical model. The developed model could also predict the thermally induced deformations produced in the mould and identify where this phenomenon would eventually lead to defects in the shape of the parts. The influence of three different temperatures of the insert at 25 °C, 50 °C and 100 °C on the failure of the insert was investigated. Also a detailed discussion about the solidification and temperature changes is given.
关键词： Finite element modelling,Vat photopolymerization,Injection moulding,Soft tooling,Additive manufacturing
更新于2025-09-23 15:22:29
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A novel method for producing solid polymer microneedles using laser ablated moulds in an injection moulding process
摘要： Microneedle arrays are minimally invasive devices which offer a pain free, straightforward and efficient method for transdermal drug delivery. Manufacturing these micro-systems represents a real challenge and a mass production process with high volume outputs at low cost is lacking. In this study, we present a novel method to produce polymer microneedles using laser ablated moulds in an injection moulding process. We successfully created cone-shaped micro holes with low tip radii in a tool steel mould, using a femtosecond laser with a cross-hatching strategy. Finally, the attained mould was used in an injection moulding process to replicate polypropylene microneedles.
关键词： Injection Moulding,Microneedles,Laser machining,Micro Manufacturing
更新于2025-09-19 17:13:59
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3D Printing of Metallic Microstructured Mould Using Selective Laser Melting for Injection Moulding of Plastic Microfluidic Devices
摘要： A new method, a 3D printing technique, in particular, selective laser melting (SLM), has been used to fabricate moulds for the injection moulding of thermoplastic micro?uidic chips that are suitable for prototyping and early stage scale-up. The micro metallic patterns are printed on to a pre-?nished substrate to form a microstructured mould. The dimensional accuracy, surface morphology, bonding strength between the printed patterns and substrate, as well as the microstructure of micro features were all characterized. A micro?uidic mould was successfully printed and used directly for injection moulding of cyclic ole?n copolymer (COC) micro?uidic chips, which were used subsequently to successfully monitor nitrite concentrations in environmental water. The characterization indicated that this new process can be used for fast fabrication of mould tools for injection moulding/hot embossing micro?uidic devices. It is faster, more ?exible and less expensive than conventional micro-machining processes, although the accuracy and ?nish are still needed to improve though process optimization and hybrid SLM and machining processes.
关键词： 3D printing,micro features,selective laser melting (SLM),injection moulding
更新于2025-09-11 14:15:04
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Design with Concurrent Approach: Development and Flow Analysis of Injection Mould Tool for Computer Monitor Lamp Holder
摘要： The plastic product manufacturing industry has been growing rapidly in recent years. One of the most popular processes for making plastic parts is injection moluding. The design of injection mould is critically important to product quality and efficient product processing. Mould-making companies, who wish to maintain the competitive edge, desire to shorten both design and manufacturing leading times by applying a systematic mould design process. The mould industry is an important support industry during the product development process, serving as an important link between the product designer and manufacturer. Product development has changed from the traditional serial process of design, followed by manufacture, to a more organized concurrent process where design and manufacture are considered at a very early stage of design. The research presents the basic structure of two plate injection mould design, injection moulding machine selection, process analysis of the injection mould design using mould flow analysis to optimize the mould cost in the design stage. This injection mould design system covers both the mould design process and mould knowledge management. In this work, CAE tools have been used in the design stage to reduce the losses to obtain the shortened lead time, high quality and achieving low cost of the mould. The design of an injection process involves the simultaneous consideration of plastic part design, mould design and injection moulding machine selection, production scheduling and cost as early as possible in the design stage. The result indicated that conventional method will consume more time and also increases the cost of machining and delay in dispatching the product. If change in design happens before pre-production and after production by trial and error method then there will be a drastic increase in design change cost which effects on cycle time, waste of raw material, increase in process time and wastage of labour cost. These entire draw backs are eliminated by using computer aided design and computer aided engineering technology for mould design and manufactured in very short period of time with minimum cost. The future scope of work is to include cooling, warpage and fatigue analysis to optimize tool design and tool life.
关键词： Plastic injection moulding,Process analysis,Moulding conditions,Flow Analysis
更新于2025-09-10 09:29:36