scholarly journals A Soft Tooling Process Chain for Injection Molding of a 3D Component with Micro Pillars

10.3791/57335 ◽  
2018 ◽  
Author(s):  
Yang Zhang ◽  
David Bue Pedersen ◽  
Michael Mischkot ◽  
Matteo Calaon ◽  
Federico Baruffi ◽  
...  
Keyword(s):  
Injection Molding ◽  
Process Chain ◽  
Micro Pillars

scholarly journals A Soft Tooling process chain employing Additive Manufacturing for injection molding of a 3D component with micro pillars

2017 ◽  
Vol 27 ◽  
pp. 138-144 ◽  
Author(s):  
Yang Zhang ◽  
David Bue Pedersen ◽  
Asger Segebrecht Gøtje ◽  
Michael Mischkot ◽  
Guido Tosello
Keyword(s):  
Additive Manufacturing ◽  
Injection Molding ◽  
Process Chain ◽  
Micro Pillars

scholarly journals Hybrid Process Chain for the Integration of Direct Ink Writing and Polymer Injection Molding

Micromachines ◽  
2020 ◽  
Vol 11 (5) ◽  
pp. 509 ◽  
Author(s):  
Dario Loaldi ◽  
Leonardo Piccolo ◽  
Eric Brown ◽  
Guido Tosello ◽  
Corey Shemelya ◽  
...  
Keyword(s):  
Injection Molding ◽  
Polymer System ◽  
Polymer Melt ◽  
Hybrid Process ◽  
Direct Write ◽  
Mold Surface ◽  
Direct Writing ◽  
Process Chain ◽  
Polymer Injection ◽  
Functional Features

The integration of additive manufacturing direct-writing technologies with injection molding provides a novel method to combine functional features into plastic products, and could enable mass-manufacturing of custom-molded plastic parts. In this work, direct-write technology is used to deposit conductive ink traces on the surface of an injection mold. After curing on the mold surface, the printed trace is transferred into the plastic part by exploiting the high temperature and pressure of a thermoplastic polymer melt flow. The transfer of the traces is controlled by interlocking with the polymer system, which creates strong plastic/ink interfacial bonding. The hybrid process chain uses designed mold/ink surface interactions to manufacture stable ink/polymer interfaces. Here, the process chain is proposed and validated through systematic interfacial analysis including feature fidelity, mechanical properties, adhesion, mold topography, surface energy, and hot polymer contact angle.

Design and Experimental Validation of a Process Chain for Thin Components Manufacturing by Micro Injection Molding Process

2021 ◽  
Author(s):  
Vincenzo Bellantone ◽  
Fulvio Lavecchia ◽  
Rossella Surace ◽  
Onofrio Spadavecchia ◽  
Francesco Modica ◽  
...  
Keyword(s):  
Injection Molding ◽  
Rapid Development ◽  
Micro Milling ◽  
Surface Finishing ◽  
Injection Molding Process ◽  
Manufacturing Cost ◽  
Process Chain ◽  
Molding Process ◽  
Micro Injection Molding ◽  
Micro Features

Abstract Micro applications, especially in biomedical and optical sectors, require the fabrication of thin polymeric parts which can be commonly realized by micro injection molding process. However, this process is characterized by a relevant constraint regarding the tooling. Indeed, the design and manufacturing of molds could be a very time-consuming step and so, a significant limitation for the rapid development of new products. Moreover, if the design displays challenging micro-features, their realization could involve the use of more than one mold for the fabrication of a single thin part. Therefore, a proper integration of different manufacturing micro technologies may represent an advantageous method to realise such polymeric thin micro features. In this work, a micro-manufacturing process chain including stereolithography, micro milling and micro injection molding is reported. The mold for the micro injection molding process was fabricated by means of stereolithography and micro milling, which allowed to produce low-cost reconfigurable modular mold, composed by an insert support and a removable insert. The assessment of the proposed process chain was carried out by evaluating the dimensions and the surface finishing and texturing of the milled mold cavities and molded components. Finally, a brief economic analysis compares three process chains for fabricating the micro mold showing that proposed one reduces manufacturing cost of almost 61% with the same production time.

scholarly journals Value chain and production cost optimization by integrating additive manufacturing in injection molding process chain

2018 ◽  
Vol 100 (1-4) ◽  
pp. 783-795 ◽  
Author(s):  
Guido Tosello ◽  
Alessandro Charalambis ◽  
Laoucine Kerbache ◽  
Michael Mischkot ◽  
David Bue Pedersen ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Injection Molding ◽  
Value Chain ◽  
Production Cost ◽  
Cost Optimization ◽  
Injection Molding Process ◽  
Process Chain ◽  
Molding Process

Filling of Microarray Fabricated by Micro Powder Injection Molding

2017 ◽  
Vol 898 ◽  
pp. 1171-1176 ◽  
Author(s):  
Lin Liu ◽  
M.X. Qi ◽  
Z.Q. Xie ◽  
Z.Y. He ◽  
F. Ming
Keyword(s):  
Injection Molding ◽  
Volume Fraction ◽  
Fluid Model ◽  
Flow Analysis ◽  
Mold Temperature ◽  
Powder Injection Molding ◽  
Powder Injection ◽  
Two Fluid Model ◽  
Micro Pillars ◽  
Micro Cavity

Flow analysis during injection molding is crucial for dimensional control in micro powder injection molding. Numerical simulation of injection molding of ZrO2 microarray based on in-house feedstock was conducted. A powder-binder two fluid model was developed to analyze temperature, viscosity and powder volume fraction of the feedstock for micro pillars of different dimensions with diameters of 0.2, 0.5 and 1 mm, respectively. In general the binder temperature decreased with size reduction of the micro cavity caved on the silicon wafer and increased with mold temperature. The micro pillars of φ0.2 mm exhibited the highest viscosity, which indicated difficulty for filling during injection molding. An increase in mold temperature facilitated the decrease of the feedstock viscosity, which improved the filling of the micro cavities. Powder-binder segregation became evident as the size of the micro cavities reduced to 0.2 mm.

scholarly journals Development of Process Chain for Micro-Injection Molding

Procedia CIRP ◽  
2020 ◽  
Vol 95 ◽  
pp. 584-589
Author(s):  
H. Büttner ◽  
U. Maradia ◽  
M. Suarez ◽  
J. Stirnimann ◽  
K. Wegener
Keyword(s):  
Injection Molding ◽  
Process Chain ◽  
Micro Injection Molding
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