Design, Optimization and Validation of Conformal Cooling Technique for Additively Manufactured Mold Insert

Injection molding is a cyclic process comprising of cooling phase as the largest part of this cycle. Providing efficient cooling in lesser cycle times is of significant importance in the molding industry. Conformal cooling is a proven technique for reduction in cycle times for injection molding. In this study, we have replaced a conventional cooling circuit with an optimized conformal cooling circuit in an injection molding tool (mold). The required heat transfer rate, coolant flow rate and diameter of channel was analytically calculated. Hybrid Laser powder bed fusion technique was used to manufacture this mold tool with conformal channels. The material used for manufacturing mold was maraging steel (M300). Thermal efficiency of the conformal channels was experimentally calculated using thermal imaging. Autodesk MoldFlow software was used to simulate and predict the cooling time required using conformal cooling channels. The results showed a decrease in cooling time and increase in cooling efficiency with the help of conformal cooling in additively manufactured mold insert.

The Relationship between a Defined Microstructure within the Mold Surface and the Corresponding Roughness on the Part: A Systematic Study on Particle Size, Filler-, and Compatibilizer Content

The perception of a surface and its haptic properties are significantly influenced by roughness and microstructure, respectively, whereby non-negligible parameters include friction, contact area, temperature, and humidity between the human finger and the examined surface. In particular, for a scientific investigation on haptic influences, the production of samples with a defined surface roughness is indispensable. The aim of this study is to analyze the impact of various mold insert roughnesses combined with the influences of particle size, filler-, and compatibilizer content on impression quality. An unfilled high density polyethylene was chosen as a reference for the impression quality investigations, while fillers with significantly different particle sizes and a compatibilizer were used to produce proprietary compounds. Injection molded parts were manufactured utilizing mold inserts with three different line roughness values. To support the obtained results, a multivariate analysis of variance, a simulation of the filling phase as well as a rheological material characterization were conducted. The results revealed that (i) the impression quality can be independent of the applied insert roughness based on the filler particle size that was studied, (ii) an increasing on both filler particle size and compatibilizer content raise the sample roughness as a function of the penetration ability of the filler into the insert valleys, and (iii) with a higher insert roughness, the thermoplastic moldings generally exhibit a significantly smoother topography. An assumed correlation between part roughness and melt viscosity could not be confirmed.

Experimental Investigation and Molecular Dynamics Simulation on the Anti-Adhesion Behavior of Alkanethiols on Nickel Insert in Micro Injection Molding

Due to the adhesion between the polymer melt and nickel (Ni) mold insert in the micro injection molding process, deformation defects frequently occur when the microstructures are demolded from the insert. In this study, self-assembled alkanethiols were applied to modify the surface of Ni mold insert to reduce its surface energy. Experimental trials were undertaken to explore the effect of alkanethiols coating on the replication quality. After that, molecular dynamics (MD) simulation was then used to investigate the adhesion behavior between the self-assembled coating and polypropylene (PP) by establishing three different types of alkanethiol material. The interaction energy, the potential energy change and radial distribution function were calculated to study the anti-adhesion mechanism. Experimental results show that all the three coatings can effectively decrease the adhesion and therefore promote the replication fidelity. It is demonstrated in MD simulation that the adhesion mainly comes from the van der Waals (vdW) force at the interface. The arrangement of sulfur atom on the Ni surface results in different absorbing behaviors. Compared with that of the PP–Ni interface, the interfacial energy and adhesion work after surface treatment is significantly reduced.

Design of Precision Hot Embossing Machine for Micro-Patterning on PMMA

A microfluidic chip requires micro-channels to be created on a substrate. This paper focuses on the design and development of a precision hot embossing machine for replication of microstructures on a PMMA substrate. Kinematic coupling using three spherical balls in radial v-grooves is used to achieve precise positioning of the mold insert with the base. Flexure based parallel guidance mechanism is used for one DOF motion required for the embossing process. The mechanism allows the motion of the mold normal to the substrate surface. Flexure based kinematic coupling with the thermal center is designed to mitigate thermal stress build-up during heating and cooling of the mold insert. An Arduino-based micro-controller is developed to control the temperature profile during the process. A prototype is fabricated and experiments are performed with an aluminium mold insert on a PMMA substrate. The result shows the feasibility of the concept and the set-up can be used to develop a cost-effective precision hot embossing machine for creating micro-patterns for microfluidic applications.

The potential of metal epoxy composite (MEC) as hybrid mold inserts in rapid tooling application: a review

Purpose Rapid tooling (RT) integrated with additive manufacturing technologies have been implemented in various sectors of the RT industry in recent years with various kinds of prototype applications, especially in the development of new products. The purpose of this study is to analyze the current application trends of RT techniques in producing hybrid mold inserts. Design/methodology/approach The direct and indirect RT techniques discussed in this paper are aimed at developing a hybrid mold insert using metal epoxy composite (MEC) in increasing the speed of tooling development and performance. An extensive review of the suitable development approach of hybrid mold inserts, material preparation and filler effect on physical and mechanical properties has been conducted. Findings Latest research studies indicate that it is possible to develop a hybrid material through the combination of different shapes/sizes of filler particles and it is expected to improve the compressive strength, thermal conductivity and consequently increasing the hybrid mold performance (cooling time and a number of molding cycles). Research limitations/implications The number of research studies on RT for hybrid mold inserts is still lacking as compared to research studies on conventional manufacturing technology. One of the significant limitations is on the ways to improve physical and mechanical properties due to the limited type, size and shape of materials that are currently available. Originality/value This review presents the related information and highlights the current gaps related to this field of study. In addition, it appraises the new formulation of MEC materials for the hybrid mold inserts in injection molding application and RT for non-metal products.

Producing Hollow Polymer Microneedles Using Laser Ablated Molds in an Injection Molding Process

Microneedle arrays contain needle-like microscopic structures which facilitate drug or vaccine delivery in a minimally invasive way. However, producing hollow microneedles is currently limited by expensive, time consuming and complex microfabrication techniques. In this paper, a novel method to produce hollow polymer microneedles is presented. This method utilizes a femtosecond laser to create hollow microneedle cavities in a mold insert. This mold insert is used in an injection molding process, to replicate polymethyl methacrylate microneedles. The combined effect of the mold temperature, volumetric injection rate and melt temperature on the replication fidelity was evaluated. It was found that the combination of high injection molding parameters facilitated the replication. Furthermore, the functionality of the manufactured hollow microneedles was successfully tested by injecting a controlled flow of colored water into an agarose matrix. The developed methodology enables the production of low-cost, high-volume microneedle devices, which could be a key asset for large scale vaccination campaigns.

Micro Injection Molding of Thin Cavities Using Stereolithography for Mold Fabrication

At the present time, there is a growing interest in additive manufacturing (AM) technologies and their integration into current process chains. In particular, the implementation of AM for tool production in micro injection molding (µ-IM), a well-established process, could introduce many advantages. First of all, AM could avoid the need for the time-consuming and expensive fabrication of molds for small series of customized products. In this work, the feasibility, quality, and reliability of an AM/µ-IM process chain were evaluated by designing and fabricating mold inserts for µ-IM by stereolithography (SLA) technology; the mold inserts were characterized and tested experimentally. The selected geometry is composed of four thin cavities: This particular feature represents an actual challenge for both the SLA and µ-IM perspective due to the large surface-to-volume ratio of the cavity. Two different materials were used for the mold fabrication, showing sharply different performance in terms of endurance limit and cavity degradation. The obtained results confirm that the µ-IM process, exploiting an SLA fabricated mold insert, is feasible but requires great accuracy in material choice, mold design, fabrication, and assembly.

Self-Assembled Monolayers of Alkanethiols on Nickel Insert: Characterization of Friction and Analysis on Demolding Quality in Microinjection Molding

When the part geometry scaling down from macro to microscale level, the size-induced surface effect becomes significant in the injection molding process. The adhesion between polymer and nickel (Ni) mold insert during the process can lead to defects in necking, warping and deformation of microstructure. In this study, the self-assembled monolayers (SAMs) with low surface energy were deposited on the Ni surface to reduce the adhesion and further improve the demolding quality of the microstructure. Results show that the alkyl mercaptan SAMs with chemical bonds and close alignment can be successfully deposited on the surface of Ni by the solution deposition method. The contact angle, surface free energy, and friction coefficient before and after anti-adhesion treatment on the surface of mold insert were measured. In addition, the anti-adhesion properties of different alkyl mercaptan materials and the correspondingly replication quality of microstructure parts after injection molding were analyzed. It is found that the Ni mold insert treated by the perfluorodecanethiol has the best wear resistance and still shows good reproducibility at the 100th demolding cycle.

Hybrid Mold: Comparative Study of Rapid and Hard Tooling for Injection Molding Application Using Metal Epoxy Composite (MEC)

The mold-making industry is currently facing several challenges, including new competitors in the market as well as the increasing demand for a low volume of precision moldings. The purpose of this research is to appraise a new formulation of Metal Epoxy Composite (MEC) materials as a mold insert. The fabrication of mold inserts using MEC provided commercial opportunities and an alternative rapid tooling method for injection molding application. It is hypothesized that the addition of filler particles such as brass and copper powders would be able to further increase mold performance such as compression strength and thermal properties, which are essential in the production of plastic parts for the new product development. This study involved four phases, which are epoxy matrix design, material properties characterization, mold design, and finally the fabrication of the mold insert. Epoxy resins filled with brass (EB) and copper (EC) powders were mixed separately into 10 wt% until 30 wt% of the mass composition ratio. Control factors such as degassing time, curing temperature, and mixing time to increase physical and mechanical properties were optimized using the Response Surface Method (RSM). The study provided optimum parameters for mixing epoxy resin with fillers, where the degassing time was found to be the critical factor with 35.91%, followed by curing temperature with 3.53% and mixing time with 2.08%. The mold inserts were fabricated for EB and EC at 30 wt% based on the optimization outcome from RSM and statistical ANOVA results. It was also revealed that the EC mold insert offers better cycle time compared to EB mold insert material.