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Increasing the Sustainability of the Hybrid Mold Technique through Combined Insert Polymeric Material and Additive Manufacturing Method Design

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  • Ellen Fernandez

    (Centre for Polymer and Material Technologies, Department of Materials, Textile and Chemical Engineering, Ghent University, 9000 Gent, Belgium)

  • Mariya Edeleva

    (Laboratory for Chemical Technology, Department of Materials, Textile and Chemical Engineering, Ghent University, 9000 Gent, Belgium)

  • Rudinei Fiorio

    (Centre for Polymer and Material Technologies, Department of Materials, Textile and Chemical Engineering, Ghent University, 9000 Gent, Belgium)

  • Ludwig Cardon

    (Centre for Polymer and Material Technologies, Department of Materials, Textile and Chemical Engineering, Ghent University, 9000 Gent, Belgium)

  • Dagmar R. D’hooge

    (Laboratory for Chemical Technology, Department of Materials, Textile and Chemical Engineering, Ghent University, 9000 Gent, Belgium
    Centre for Textile Science and Engineering, Department of Materials, Textile and Chemical Engineering, Ghent University, 9000 Gent, Belgium)

Abstract

To reduce plastic waste generation from failed product batches during industrial injection molding, the sustainable production of representative prototypes is essential. Interesting is the more recent hybrid injection molding (HM) technique, in which a polymeric mold core and cavity are produced via additive manufacturing (AM) and are both placed in an overall metal housing for the final polymeric part production. HM requires less material waste and energy compared to conventional subtractive injection molding, at least if its process parameters are properly tuned. In the present work, several options of AM insert production are compared with full metal/steel mold inserts, selecting isotactic polypropylene as the injected polymer. These options are defined by both the AM method and the material considered and are evaluated with respect to the insert mechanical and conductive properties, also considering Moldex3D simulations. These simulations are conducted with inputted measured temperature-dependent AM material properties to identify in silico indicators for wear and to perform cooling cycle time minimization. It is shown that PolyJetted Digital acrylonitrile-butadiene-styrene (ABS) polymer and Multi jet fusioned (MJF) polyamide 11 (PA11) are the most promising. The former option has the best durability for thinner injection molded parts, and the latter option the best cooling cycle times at any thickness, highlighting the need to further develop AM options.

Suggested Citation

  • Ellen Fernandez & Mariya Edeleva & Rudinei Fiorio & Ludwig Cardon & Dagmar R. D’hooge, 2022. "Increasing the Sustainability of the Hybrid Mold Technique through Combined Insert Polymeric Material and Additive Manufacturing Method Design," Sustainability, MDPI, vol. 14(2), pages 1-17, January.
    • Handle: RePEc:gam:jsusta:v:14:y:2022:i:2:p:877-:d:723685
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    References listed on IDEAS

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    1. Berman, Barry, 2012. "3-D printing: The new industrial revolution," Business Horizons, Elsevier, vol. 55(2), pages 155-162.
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