Search results

Polyurethane (PUR) foam parts are traditionally manufactured using metallic molds, an unsuitable approach for prototyping purposes. Thus, rapid tooling of disposable molds using fused filament fabrication (FFF) with polylactic acid (PLA) and glycol-modified polyethylene terephthalate (PETG) is proposed as an economical, simpler and faster solution compared to traditional metallic molds or three-dimensional (3D) printing with other difficult-to-print thermoplastics, which are prone to shrinkage and delamination (acrylonitrile butadiene styrene, polypropilene-PP) or high-cost due to both material and printing equipment expenses (PEEK, polyamides or polycarbonate-PC). The purpose of this study has been to evaluate the ease of release of PUR foam on these materials in combination with release agents to facilitate the mulding/demoulding process.

PETG, PLA and hardenable polylactic acid (PLA 3D870) have been evaluated as mold materials in combination with aqueous and solvent-based release agents within a full design of experiments by three consecutive molding/demolding cycles.

PLA 3D870 has shown the best demoldability. A mold expressly designed to manufacture a foam cushion has been printed and the prototyping has been successfully achieved. The demolding of the part has been easier using a solvent-based release agent, meanwhile the quality has been better when using a water-based one.

The combination of PLA 3D870 and FFF, along with solvent-free water-based release agents, presents a compelling low-cost and eco-friendly alternative to traditional metallic molds and other 3D printing thermoplastics. This innovative approach serves as a viable option for rapid tooling in PUR foam molding.

The purpose of this study is to demonstrate and characterise a soft-tooled micro-injection moulding process through in-line measurements and surface metrology using a data-intensive approach.

A soft tool for a demonstrator product that mimics the main features of miniature components in medical devices and microsystem components has been designed and fabricated using material jetting technique. The soft tool was then integrated into a mould assembly on the micro-injection moulding machine, and mouldings were made. Sensor and data acquisition devices including thermal imaging and injection pressure sensing have been set up to collect data for each of the prototypes. Off-line dimensional characterisation of the parts and the soft tool have also been carried out to quantify the prototype quality and dimensional changes on the soft tool after the manufacturing cycles.

The data collection and analysis methods presented here enable the evaluation of the quality of the moulded parts in real-time from in-line measurements. Importantly, it is demonstrated that soft-tool surface temperature difference values can be used as reliable indicators for moulding quality. Reduction in the total volume of the soft-tool moulding cavity was detected and quantified up to 100 cycles. Data collected from in-line monitoring was also used for filling assessment of the soft-tool moulding cavity, providing about 90% accuracy in filling prediction with relatively modest sensors and monitoring technologies.

This work presents a data-intensive approach for the characterisation of soft-tooled micro-injection moulding processes for the first time. The overall results of this study show that the product-focussed data-rich approach presented here proved to be an essential and useful way of exploiting additive manufacturing technologies for soft-tooled rapid prototyping and new product introduction.

This study aims to investigate a systematic approach to the production and use of additively manufactured injection mould inserts in product development (PD) processes. For this purpose, an evaluation of the additive tooling design method (ATDM) is performed.

The evaluation of the ATDM is conducted within student workshops, where students develop products and validate them using AT-prototypes. The evaluation process includes the analysis of work results as well as the use of questionnaires and participant observation.

This study shows that the ATDM can be successfully used to assist in producing and using AT mould inserts to produce valid AT prototypes. As a reference for the implementation of AT in industrial PD, extracts from the work of the student project groups and suitable process parameters for prototype production are presented.

This paper presents the application and evaluation of a method to support AT in PD that has not yet been scientifically evaluated.

This study aims to enhance merging of additive manufacturing (AM) techniques with powder injection molding (PIM). In this way, the prototypes could be 3D-printed and mass production implemented using PIM. Thus, the surface properties and mechanical performance of parts produced using powder/polymer binder feedstocks [material extrusion (MEX) and PIM] were investigated and compared with powder manufacturing based on direct metal laser sintering (DMLS).

PIM parts were manufactured from 17-4PH stainless steel PIM-quality powder and powder intended for powder bed fusion compounded with a recently developed environmentally benign binder. Rheological data obtained at the relevant temperatures were used to set up the process parameters of injection molding. The tensile and yield strengths as well as the strain at break were determined for PIM sintered parts and compared to those produced using MEX and DMLS. Surface properties were evaluated through a 3D scanner and analyzed with advanced statistical tools.

Advanced statistical analyses of the surface properties showed the proximity between the surfaces created via PIM and MEX. The tensile and yield strengths, as well as the strain at break, suggested that DMLS provides sintered samples with the highest strength and ductility; however, PIM parts made from environmentally benign feedstock may successfully compete with this manufacturing route.

This study addresses the issues connected to the merging of two environmentally efficient processing routes. The literature survey included has shown that there is so far no study comparing AM and PIM techniques systematically on the fixed part shape and dimensions using advanced statistical tools to derive the proximity of the investigated processing routes.

This paper is devoted to prepare micro-cone structure with variable cross-section size by Stereo Lithography Appearance (SLA)-based 3D additive manufacturing technology. It is mainly focused on analyzing the forming mechanism of equipment and factors affecting the forming quality and accuracy, investigating the influence of forming process parameters on the printing quality and optimization of the printing quality. This study is expected to provide a µ-SLA surface preparation technology and process parameters selection with low cost, high precision and short preparation period for microstructure forming.

The µ-SLA process is optimized based on the variable cross-section micro-cone structure printing. Multi-index analysis method was used to analyze the influence of process parameters. The process parameter influencing order is determined and validated with flawless micro array structure.

After the optimization analysis of the top diameter size, the bottom diameter size and the overall height, the influence order of the printing process parameters on the quality of the micro-cone forming is: exposure time (B), print layer thickness (A) and number of vibrations (C). The optimal scheme is A1B3C1, that is, the layer thickness of 5 µm, the exposure time of 3000 ms and the vibration of 64x. At this time, the cone structure with the bottom diameter of 50 µm and the cone angle of 5° could obtain a better surface structure.

This study is expected to provide a µ-SLA surface preparation technology and process parameters selection with low cost, high precision and short preparation period for microstructure forming.

This paper aims to realize an in-situ quality inspection system rapidly for new injection molding (IM) tasks via transfer learning (TL) approach and automation technology.

The proposed in-situ quality inspection system consists of an injection machine, USB camera, programmable logic controller and personal computer, interconnected via OPC or USB communication interfaces. This configuration enables seamless automation of the IM process, real-time quality inspection and automated decision-making. In addition, a MobileNet-based deep learning (DL) model is proposed for quality inspection of injection parts, fine-tuned using the TL approach.

Using the TL approach, the MobileNet-based DL model demonstrates exceptional performance, achieving validation accuracy of 99.1% with the utilization of merely 50 images per category. Its detection speed and accuracy surpass those of DenseNet121-based, VGG16-based, ResNet50-based and Xception-based convolutional neural networks. Further evaluation using a random data set of 120 images, as assessed through the confusion matrix, attests to an accuracy rate of 96.67%.

The proposed MobileNet-based DL model achieves higher accuracy with less resource consumption using the TL approach. It is integrated with automation technologies to build the in-situ quality inspection system of injection parts, which improves the cost-efficiency by facilitating the acquisition and labeling of task-specific images, enabling automatic defect detection and decision-making online, thus holding profound significance for the IM industry and its pursuit of enhanced quality inspection measures.

The purpose of this study is to design a closed hydrostatic guideway has the ability to resist large-side load, pitch moments and yaw moments, has good stiffness and damping characteristics, and provides certain beneficial guidance for the design of large-span closed hydrostatic guideway on the basis of providing a large vertical load bearing capacity.

The Reynolds’ equation and flow continuity equation are solved simultaneously by the finite difference method, and the perturbation method and the finite disturbance method is used for calculating the dynamic characteristics. The static and dynamic characteristics, including recess pressure, flow of lubricating oil, carrying capacity, pitch moment, yaw moment, dynamic stiffness and damping, are comprehensively analyzed.

The designed closed hydrostatic guideway has the ability to resist large lateral load, pitch moment and yaw moment and has good stiffness and damping characteristics, on the basis of being able to provide large vertical carrying capacity, which can meet the application requirements of heavy two-plate injection molding machine (TPIMM).

This paper researches static and dynamic characteristics of a large-span six-slider closed hydrostatic guideway used in heavy TPIMM, emphatically considering pitch moment and yaw moment. Some useful guidance is given for the design of large-span closed hydrostatic guideway.

Continuous fiber reinforced thermoplastic composites (CFRTPCs) with great mechanical properties and green recyclability have been widely used in aerospace, transportation, sports and leisure products, etc. However, the conventional molding technologies of CFRTPCs, with high cost and low efficiency, limit the property design and broad application of composite materials. The purpose of this paper is to study the effect of the 3D printing process on the integrated rapid manufacturing of CFRTPCs.

Tensile and flexural simulations and tests were performed on CFRTPCs. The effect of key process parameters on mechanical properties and molding qualities was evaluated individually and mutually to optimize the printing process. The micro morphologies of tensile and flexural breakages of the printed CFRTPCs were observed and analyzed to study the failure mechanism.

The results proved that the suitable process parameters for great printing qualities and mechanical properties included the glass hot bed with the microporous and solid glue coatings at 60°C and the nozzle temperature at 295°C. The best parameters of the nozzle temperature, layer thickness, feed rate and printing speed for the best elastic modulus and tensile strength were 285°C, 0.5 mm, 6.5r/min and 500 mm/min, respectively, whereas those for the smallest sectional porosity were 305°C, 0.6 mm, 5.5r/min and 550 mm/min, respectively.

This work promises a significant contribution to the improvement of the printing quality and mechanical properties of 3D printed CFRTPCs parts by the optimization of 3D printing processes.

This study aims to present a vision-guided robotic system design for application in vat photopolymerization additive manufacturing (AM), enabling vat photopolymerization AM hybrid with injection molding process.

In the system, a robot equipped with a camera and a custom-made gripper as well as driven by a visual servoing (VS) controller is expected to perceive objective, handle variation, connect multi-process steps in soft tooling process and realize automation of vat photopolymerization AM. Meanwhile, the vat photopolymerization AM printer is customized in both hardware and software to interact with the robotic system.

By ArUco marker-based vision-guided robotic system, the printing platform can be manipulated in arbitrary initial position quickly and robustly, which constitutes the first step in exploring automation of vat photopolymerization AM hybrid with soft tooling process.

The vision-guided robotic system monitors and controls vat photopolymerization AM process, which has potential for vat photopolymerization AM hybrid with other mass production methods, for instance, injection molding.

This study aims to produce homogenously prepared polymer composites by adding two different strontium aluminate derivatives (Sr4Al14O25 and SrAl2O4) to urea-formaldehyde (UF) at different mass concentrations. In the context of this work those strontium-based derivatives were compared in terms of mechanical and luminescent characteristics. Additionally, sodium bicarbonate was integrated with the prepared composites to eliminate/minimize darkening problem, which might arise from the oxidation of Eu +2 to Eu2O3, on the surface of strontium aluminate/urea-formaldehyde composites.

In this study, strontium aluminate/UF composite materials were produced using a compression molding technique. Their mechanical, thermomechanical and luminescence properties were investigated via various characterization methods. Particle size analysis was used to characterize phosphor derivatives, whereas scanning electron microscopy with energy dispersive X-ray spectroscopy (SEM-EDX) was conducted for morphological examination.

The darkening problem was prevented by the introduction of sodium bicarbonate into the composite systems. Based on the characterization and test results, the only addition of strontium aluminate reduced the mechanical properties. However, it was seen that the introduction of sodium bicarbonate into the composites improved those properties positively. The appropriate amounts of strontium aluminate and sodium bicarbonate were determined by conducting an experimental optimization study. The optimum composition of the composite materials was obtained by introducing 2% phosphor and 3% NaHCO₃.

The approach used in this study has provided a method to solve the darkening problem, which degrades the aesthetic appearance in industrial production.