Abstract
Liquid silicone rubber (LSR) parts have many excellent properties, such as good thermal stability, low toxicity, and self-lubrication. It is a cost-effective approach for the pilot run using polymer rapid tools. However, the cost of the commercially available materials for fabricating polymer rapid tools is inexpensive. In this study, a low-cost mixture comprising aluminum (Al) powder and epoxy resin for fabricating LSR injection mold inserts was developed. The tensile strength, hardness, compressive strength, impact strength, and heating rate of the test specimens fabricated by the mixture developed in this study were about 85%, 97%, 89%, 99%, and 82% of the specimens fabricated by commercially available materials. It was found that the developed materials are very practical and provide the greatest applications potential in the LSRIM industry under similarity in mechanical properties, physical property, and mold longevity with commercial materials without consideration of the labor costs. The Al powder and epoxy resin mixed weight ratio of 65:35 is the optimum mixing ratio for manufacturing LSR molding injection mold. The production costs of a LSR injection mold insert fabricated the material developed in this study was only about one-eighth compared with those fabricated from commercially available materials. After 200 molding cycles, the increases in surface roughness of an LSR injection mold fabricated by mixture developed in this study are very similar to those fabricated from commercially available materials.
Similar content being viewed by others
References
Ou H, Sahli M, Barrière T, Gelin JC (2017) Multiphysics modelling and experimental investigations of the filling and curing phases of bi-injection moulding of thermoplastic polymer/liquid silicone rubbers. Int J Adv Manuf Technol 92(9–12):3871–3882
Hopmann C, Behmenburg C, Recht U, Zeuner K (2014) Injection molding of superhydrophobic liquid silicone rubber surfaces. Silicon 6(1):35–43
Issa M, Petkovic D, Pavlovic ND, Zentner L (2013) Sensor elements made of conductive silicone rubber for passively compliant gripper. Int J Adv Manuf Technol 69(5–8):1527–1536
Park H, Cha B, Cho S, Kim D, Choi JH, Pyo BG, Rhee B (2016) A study on the estimation of plastic deformation of metal insert parts in multi-cavity injection molding by injection-structural coupled analysis. Int J Adv Manuf Technol 83(9):2057–2069
Qiu J, Lai X, Fang W, Li H, Zeng X (2017) An efficient strategy for simultaneously improving tracking resistance and flame retardancy of addition-cure liquid silicone rubber. Polym Degrad Stab 144:176–186
Wu J, Zhang C, Su B, Dong J, Wang Y, Gond BK (2018) New method for studying the macro-micro contact properties between smooth metal and silicone rubber. Int J Adv Manuf Technol 96(5–8):1761–1767
Harkousa A, Colomines G, Leroyb E, Mousseaua P, Deterrea R (2016) The kinetic behavior of liquid silicone rubber: a comparison between thermal and rheological approaches based on gel point determination. React Funct Polym 101:20–27
Ou H, Sahli M, Barriere T, Gelindd JC (2017) Experimental characterisation and modelling of rheokinetic properties of different silicone elastomers. Int J Adv Manuf Technol 92(9–12):4199–4211
Rey T, Le Cam J-B, Chagnon G, Favier D, Rebouah M, Razan F, Robin E, Didier P, Heller L, Faure S, Janouchova K (2014) An original architectured NiTi silicone rubber structure for biomedical applications. Mater Sci Eng C 45:184–190
Yuan B, Wang Z, Fang W, Li J (2018) Rheological experimental properties and numerical modeling of a pressure-transmitting silicone rubber used in sheet metal flexible-die forming. Int J Adv Manuf Technol 95(5–8):1697–1714
Kaitainen S, Kutvonen A, Suvanto M, Pakkanen TT, Lappalainen R, Myllymaa S (2014) Liquid silicone rubber (LSR)-based dry bioelectrodes: The effect of surface micropillar structuring and silver coating on contact impedance. Sensors Actuators A Phys 206:22–29
Liu T, Zeng X, Fang W, Lai X, Li H (2017) Synthesis of a novel hydantoin-containing silane and its effect on the tracking and bacteria resistance of addition-cure liquid silicone rubber. Appl Surf Sci 423:630–640
Seitz V, Arzt K, Mahnel S, Rapp C, Schwaminger S, Hoffstetter M, Wintermantel E (2016) Improvement of adhesion strength of self-adhesive silicone rubber on thermoplastic substrates—comparison of an atmospheric pressure plasma jet (APPJ) and a pyrosil flame. Int J Adhes Adhes 66:65–72
AlMangour B, Yang JM (2017) Understanding the deformation behavior of 17-4 precipitate hardenable stainless steel produced by direct metal laser sintering using micropillar compression and TEM. Int J Adv Manuf Technol 90(1–4):119–126
Scharowsky T, Bauereib A, Korner C (2017) Influence of the hatching strategy on consolidation during selective electron beam melting of Ti-6Al-4 V. Int J Adv Manuf Technol 92(5–8):2809–2818
Liu Y, Yang Y, Wang D (2016) A study on the residual stress during selective laser melting (SLM) of metallic powder. Int J Adv Manuf Technol 87(1–4):647–656
Leite JL, Salmoria GV, Paggi RA, Ahrens CH, Pouzada AS (2012) Microstructural characterization and mechanical properties of functionally graded PA12/HDPE parts by selective laser sintering. Int J Adv Manuf Technol 59(5–8):583–591
Lin H, Luo H, Huang W, Zhang X, Yao G (2016) Diffusion bonding in fabrication of aluminum foam sandwich panels. J Mater Process Technol 230:35–41
Gorunov AI, Gilmutdinov AK (2016) Study of the effect of heat treatment on the structure and properties of the specimens obtained by the method of direct metal deposition. Int J Adv Manuf Technol 86(9–12):2567–2574
Kalentics N, Burn A, Cloots M, Logé RE (2018) 3D laser shock peening as a way to improve geometrical accuracy in selective laser melting. Int J Adv Manuf Technol 101:1247–1254. https://doi.org/10.1007/s00170-018-3033-3
Pupo Y, Monroy KP, Ciurana J (2015) Influence of process parameters on surface quality of CoCrMo produced by selective laser melting. Int J Adv Manuf Technol 80(5–8):985–995
Han J, Wu M, Ge Y, Wu J (2018) Optimizing the structure accuracy by changing the scanning strategy using selective laser melting. Int J Adv Manuf Technol 95(9–12):4439–4447
Kuo YL, Kamigaichi A, Kakehi K (2018) Characterization of Ni-Based superalloy built by selective laser melting and electron beam melting. Metall Mater Trans A 49(9):3831–3837
Kundakcıoğlu E, Lazoglu I, Poyraz Ö, Yasa E, Cizicioğlu N (2018) Thermal and molten pool model in selective laser melting process of Inconel 625. Int J Adv Manuf Technol 95(9–12):3977–3984
Ling Z, Wu J, Wang X, Li X, Zheng J (2018) Experimental study on the variance of mechanical properties of polyamide 6 during multi-layer sintering process in selective laser sintering. Int J Adv Manuf Technol 101:1227–1234. https://doi.org/10.1007/s00170-018-3004-8
Kuo CC, Lin JX (2018) Fabrication of the Fresnel lens with liquid silicone rubber using rapid injection mold. Int J Adv Manuf Technol 101:615–625. https://doi.org/10.1007/s00170-018-2964-z
Kuo CC, You ZY (2018) Development of injection molding tooling with conformal cooling channels fabricated by optimal process parameters. Int J Adv Manuf Technol 96(1–4):1003–1013
Kuo CC, Lyu SY (2018) A cost-effective approach using recycled materials to fabricate micro-hot embossing die for microfabrication. Int J Adv Manuf Technol 94(9–12):4365–4371
Kuo CC, Chen WH, Liu XZ, Liao YL, Chen WJ, Huang BY, Tsai RL (2017) Development of a low-cost wax injection mold with high cooling efficiency. Int J Adv Manuf Technol 93(5–8):2081–2088
Kuo CC, Chen WH, Zhang JW, Tsai DA, Cao YL (2017) A new method of manufacturing a rapid tooling with different cross-sectional cooling channels. Int J Adv Manuf Technol 92(9–12):3481–3487
Kuo CC, Li MR (2017) Development of sheet metal forming dies with excellent mechanical properties using additive manufacturing and rapid tooling technologies. Int J Adv Manuf Technol 90(1):21–25
Lu YC, Wu CY, Chang TK, Huang CH, Huang CH (2018) Elastoplastic behavior of highly cross-linked and vitamin E-stabilized polyethylene—a biomechanical study. Clin Biomech 59:152–158
Bergonzi L, Vettori M, Pirondi A, Moroni F, Musiari F (2018) Numerical and experimental validation of a non-standard specimen for uniaxial tensile test. Procedia Struct Integrity 12:392–403
Marras G, Careddu N (2018) Sustainable reuse of marble sludge in tyre mixtures. Res Policy 59:77–84
Egala R, Setti SG (2018) Impact characterization of epoxy LY556/ricinus communis L plant natural fiber composite materials. Mater Today Proc 5, Issue 13, Part 3:26799–26803
Safeen W, Hussain S, Wasim A, Jahanzaib M, Aziz H, Abdalla H (2016) Predicting the tensile strength, impact toughness, and hardness of friction stir-welded AA6061-T6 using response surface methodology. Int J Adv Manuf Technol 87(5–8):1765–1781
Lie HA, Nurhuda I, Setiawan Y (2014) The effect of aggregate shape and configuration to the concrete behavior. Smart Sci 2(2):85–90
Chen TH, Luo YC, Lin YJ (2017) The effect of Al on the mechanical properties and microstructure of copper-based metallic glass. Smart Sci 5(4):173–178
Fuentes-Huerta MA, González-González DS, Cantú-Sifuentes M, Praga-Alejo RJ (2018) RCM implementation on plastic injection molding machine considering correlated failure modes and small size sample. Int J Adv Manuf Technol 95(9–12):3465–3473
Kitayama S, Onuki R, Yamazaki K (2014) Warpage reduction with variable pressure profile in plastic injection molding via sequential approximate optimization. Int J Adv Manuf Technol 72(5–8):827–838
Li XP, Zhao GQ, Yang C (2014) Effect of mold temperature on motion behavior of short glass fibers in injection molding process. Int J Adv Manuf Technol 73(5–8):639–645
Tosello G, Gava A, Hansen HN, Lucchetta G (2010) Study of process parameters effect on the filling phase of micro-injection moulding using weld lines as flow markers. Int J Adv Manuf Technol 47(1–4):81–97
Karnati S, Liou FF, Newkirk JW (2019) Characterization of copper–nickel alloys fabricated using laser metal deposition and blended powder feedstocks. Int J Adv Manuf Technol:1–12. https://doi.org/10.1007/s00170-019-03553-0
Mandel M, Krüger L, Decker S (2015) Comparative corrosion studies of zirconia particle reinforced high-alloyed 14-6-6 CrMnNi-steel by potentiodynamic polarisation and one year outdoor exposure. Mater Werkst 46(10):1039–1045
Neumann A, Kramps M, Ragoß C, Maier HR, Jahnke K (2004) Histological and microradiographic appearances of Silicon Nitride and Aluminum Oxide in a rabbit femur implantation model. Mater Werkst 35(9):569–573
Li ZX, Wan Q, Li GD, Li H, Li HJ, Zhang TL, Kim HJ, Tillmann W (2019) Lubrication mechanisms of C-MoS2-Fe2O3 (Fe3O4) nano-composite lubricants at the rubbing interfaces of non-copper coated solid wires against the contact tube. Mater Werkst 50(1):52–63
Haberstroh E, Michaeli W, Henze E (2002) Simulation of the filling and curing phase in injection molding of liquid silicone rubber (LSR). J Reinf Plast Compos 21(5):461–471
Kim WW, Gang MG, Min BK, Kim WB (2014) Experimental and numerical investigations of cavity filling process in injection moulding for microcantilever structures. Int J Adv Manuf Technol 75(1–4):293–304
Liu C, Cai Z, Dai Y, Huang N, Xu F, Lao C (2018) Experimental comparison of the flow rate and cooling performance of internal cooling channels fabricated via selective laser melting and conventional drilling process. Int J Adv Manuf Technol 96(5–8):2757–2767
Ujah CO, Popoola API, Popoola OM, Aigbodion VS (2019) Optimisation of spark plasma sintering parameters of Al-CNTs-Nb nano-composite using Taguchi design of experiment. Int J Adv Manuf Technol 100(5–8):1563–1573
Funding
The authors gratefully acknowledge financial support from the Ministry of Science and Technology of Taiwan under contracts MOST 107-2221-E-131-018, MOST 106-2221-E-131-010, MOST 106-2221-E-131-011, MOST 105-2221-E-131-012, MOST 104-2221-E-131-026, and MOST 103-2221-E-131-012.
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Kuo, CC., Lin, JX. A cost-effective method for rapid manufacturing polymer rapid tools used for liquid silicone rubber injection molding. Int J Adv Manuf Technol 104, 1159–1170 (2019). https://doi.org/10.1007/s00170-019-04000-w
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-019-04000-w