Heat Dissipation Plays Critical Role for Longevity of Polymer-Based 3D-Printed Inserts for Plastics Injection Moulding
Injection moulding is a polymer processing method of choice for making plastic parts on industrial scale, but its traditional mould is made from tooling steel with time-consuming and costly production. Additive manufacturing technologies arise as an alternative for creating mould inserts at lower co...
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| Format: | Article |
| Language: | English |
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MDPI AG
2022-10-01
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| Series: | Journal of Manufacturing and Materials Processing |
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| Online Access: | https://www.mdpi.com/2504-4494/6/5/117 |
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| author | Vicente F. Moritz Gilberto S. N. Bezerra Michael Hopkins Jnr Evert Fuenmayor Suzan Günbay Conor Hayes John G. Lyons Declan M. Devine |
| author_facet | Vicente F. Moritz Gilberto S. N. Bezerra Michael Hopkins Jnr Evert Fuenmayor Suzan Günbay Conor Hayes John G. Lyons Declan M. Devine |
| author_sort | Vicente F. Moritz |
| collection | DOAJ |
| description | Injection moulding is a polymer processing method of choice for making plastic parts on industrial scale, but its traditional mould is made from tooling steel with time-consuming and costly production. Additive manufacturing technologies arise as an alternative for creating mould inserts at lower costs and shorter lead times. In this context, this study describes a series of stereolithography (SLA)-printed injection mould inserts fabricated from two photopolymer resins, utilised to mould standard tensile specimens of a commercial-grade polypropylene, aiming to evaluate effects on the polymer’s thermal and mechanical properties. Our results demonstrated that the glass fibre-filled resin inserts withstood more moulding cycles before failure, had superior mechanical properties, higher <i>T<sub>g</sub></i> and greater thermal conductivity. Calorimetric data revealed that PP thermal properties and degree of crystallinity were little affected, while mechanical testing suggests a significant effect in the elongation at break. Thus, these findings highlight the importance of adequate heat extraction during injection moulding and endorse further application of SLA mould inserts for the manufacturing of injection-moulded plastic parts in the case of prototypes or small batches, provided suitable cooling is made available, contributing to the feasibility and affordability of employing this approach for an industrial setting. |
| first_indexed | 2024-03-09T20:01:34Z |
| format | Article |
| id | doaj.art-1310dc1840bb4c4f8ea624147cf9aff9 |
| institution | Directory Open Access Journal |
| issn | 2504-4494 |
| language | English |
| last_indexed | 2024-03-09T20:01:34Z |
| publishDate | 2022-10-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj.art-1310dc1840bb4c4f8ea624147cf9aff92023-11-24T00:42:29ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942022-10-016511710.3390/jmmp6050117Heat Dissipation Plays Critical Role for Longevity of Polymer-Based 3D-Printed Inserts for Plastics Injection MouldingVicente F. Moritz0Gilberto S. N. Bezerra1Michael Hopkins Jnr2Evert Fuenmayor3Suzan Günbay4Conor Hayes5John G. Lyons6Declan M. Devine7PRISM Research Institute, Technological University of the Shannon, Dublin Rd, N37 HD68 Athlone, IrelandPRISM Research Institute, Technological University of the Shannon, Dublin Rd, N37 HD68 Athlone, IrelandPRISM Research Institute, Technological University of the Shannon, Dublin Rd, N37 HD68 Athlone, IrelandPRISM Research Institute, Technological University of the Shannon, Dublin Rd, N37 HD68 Athlone, IrelandPRISM Research Institute, Technological University of the Shannon, Dublin Rd, N37 HD68 Athlone, IrelandPRISM Research Institute, Technological University of the Shannon, Dublin Rd, N37 HD68 Athlone, IrelandPRISM Research Institute, Technological University of the Shannon, Dublin Rd, N37 HD68 Athlone, IrelandPRISM Research Institute, Technological University of the Shannon, Dublin Rd, N37 HD68 Athlone, IrelandInjection moulding is a polymer processing method of choice for making plastic parts on industrial scale, but its traditional mould is made from tooling steel with time-consuming and costly production. Additive manufacturing technologies arise as an alternative for creating mould inserts at lower costs and shorter lead times. In this context, this study describes a series of stereolithography (SLA)-printed injection mould inserts fabricated from two photopolymer resins, utilised to mould standard tensile specimens of a commercial-grade polypropylene, aiming to evaluate effects on the polymer’s thermal and mechanical properties. Our results demonstrated that the glass fibre-filled resin inserts withstood more moulding cycles before failure, had superior mechanical properties, higher <i>T<sub>g</sub></i> and greater thermal conductivity. Calorimetric data revealed that PP thermal properties and degree of crystallinity were little affected, while mechanical testing suggests a significant effect in the elongation at break. Thus, these findings highlight the importance of adequate heat extraction during injection moulding and endorse further application of SLA mould inserts for the manufacturing of injection-moulded plastic parts in the case of prototypes or small batches, provided suitable cooling is made available, contributing to the feasibility and affordability of employing this approach for an industrial setting.https://www.mdpi.com/2504-4494/6/5/1173D printed mouldsinjection mouldingadditive manufacturingstereolithographypolypropylene |
| spellingShingle | Vicente F. Moritz Gilberto S. N. Bezerra Michael Hopkins Jnr Evert Fuenmayor Suzan Günbay Conor Hayes John G. Lyons Declan M. Devine Heat Dissipation Plays Critical Role for Longevity of Polymer-Based 3D-Printed Inserts for Plastics Injection Moulding Journal of Manufacturing and Materials Processing 3D printed moulds injection moulding additive manufacturing stereolithography polypropylene |
| title | Heat Dissipation Plays Critical Role for Longevity of Polymer-Based 3D-Printed Inserts for Plastics Injection Moulding |
| title_full | Heat Dissipation Plays Critical Role for Longevity of Polymer-Based 3D-Printed Inserts for Plastics Injection Moulding |
| title_fullStr | Heat Dissipation Plays Critical Role for Longevity of Polymer-Based 3D-Printed Inserts for Plastics Injection Moulding |
| title_full_unstemmed | Heat Dissipation Plays Critical Role for Longevity of Polymer-Based 3D-Printed Inserts for Plastics Injection Moulding |
| title_short | Heat Dissipation Plays Critical Role for Longevity of Polymer-Based 3D-Printed Inserts for Plastics Injection Moulding |
| title_sort | heat dissipation plays critical role for longevity of polymer based 3d printed inserts for plastics injection moulding |
| topic | 3D printed moulds injection moulding additive manufacturing stereolithography polypropylene |
| url | https://www.mdpi.com/2504-4494/6/5/117 |
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