Skip to main content
SpringerLink
Log in

Alternative materials in moulding elements of hybrid moulds: structural integrity and tribological aspects

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Hybrid moulds are an increasingly considered alternative for prototype series or short production runs. This type of tools resorts on the use of Rapid Prototyping and Tooling (RPT) to produce the moulding elements (blocks or other inserts). This study was developed using a hybrid injection mould with exchangeable moulding elements that were produced by additive manufacturing (AM), namely vacuum epoxy casting, stereolithography and ProMetal. A full steel tool was also used as a reference. The processing conditions for the polypropylene moulded parts using the hybrid mould were monitored for pressure, temperature and ejection force. The hybrid mould performance was assessed in terms of pressure and temperature evolution during the injection cycle and the AM moulding elements for physical integrity. The data from the polypropylene moulded parts and the moulding inserts are compared with structural and rheological simulations using ANSYS Workbench and MOLDEX 3D. The results show that the hybrid mould performance and the structural integrity of the moulding elements depend on the properties of the materials used. The moulding shrinkage, when resin cores are used, is also affected by the core deformation caused by the injection pressure.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19

Similar content being viewed by others

Data availability

Not applicable

References

  1. Campbell I, Combrinck J, Beer D, Barnard L (2008) Stereolithography build time estimation based on volumetric calculations. Rapid Prototyp J 14(5):271–279

    Article  Google Scholar 

  2. Correia MS, Martinho PG, Pouzada AS (2014) The ejection force effect on the life of hybrid mould inserts produced by additive manufacturing. In: PMI 2014 - International conference on polymers and moulds innovations, Guimaraes, Portugal

    Google Scholar 

  3. Curfman WA (1989) Method of making an epoxy mold. General Motors Corporation, Detroit US Patent

    Google Scholar 

  4. Drizo A, Pegna J (2006) Environmental impacts of rapid prototyping: an overview of research to date. Rapid Prototyp J 12(2):64–71

    Article  Google Scholar 

  5. Freitas A, Soares R, Martinho PG, Pouzada AS (2012) Rapid Prototyping and Tooling in the manufacture of mould elements for large parts. In: PMI 2012 - International conference on polymers and moulds innovations, Gent, Belgium

  6. Godec D, Šercer M, Rujnic-Sokele M (2008) Influence of hybrid mould on moulded parts properties. Rapid Prototyp J 14(2):95–101

    Article  Google Scholar 

  7. Gonçalves MW, Salmoria GV, Ahrens CH, Pouzada AS (2007) Study of tribological properties of moulds obtained by stereolithography. Virtual Phys Prototyp 2(1):29–36

    Article  Google Scholar 

  8. Hopkinson N, Dickens P (2000) A comparison between stereolithography and aluminium injection moulding tooling. Rapid Prototyp J 6(4):253–258

    Article  Google Scholar 

  9. Hou B, Huang Z, Zhou H, Li D (2018) A hybrid approach for automatic parting curve generation in injection mold design. Int J Adv Manuf Technol 95:3985–4001

    Article  Google Scholar 

  10. Kruth JP, Mercelis P, Vaerenbergh JV, Froyen L, Rombouts M (2003) Advances in selective laser sintering. In: Advanced Research in Virtual and Rapid Prototyping, Leiria/Portugal

  11. Marques S, Souza AF, Miranda J, Yadroitsau I (2015) Design of conformal cooling for plastic injection moulding by heat transfer simulation. Polímeros 25(6):564–574

    Article  Google Scholar 

  12. Martinho PG, Bártolo PJ, Pouzada AS (2007) Efficient design solutions for hybrid moulds and the widening of the lifecycle of injection moulds. In: PMI 2007 - International conference on polymers and moulds innovations, Gent, Belgium

  13. Martinho PG, Bártolo PJ, Pouzada AS (2009) Hybrid moulds: effect of the moulding blocks on the morphology and dimensional properties. Rapid Prototyp J 15(1):71–82

    Article  Google Scholar 

  14. Martinho PG, Brito AM, Rodrigues SJ, Pouzada AS (2016) Hybrid moulds: the performance of moulding blocks produced by vacuum casting resins with different fillers. In: PMI 2016 - International conference on polymers and moulds innovations, Gent, Belgium

  15. Martinho PG, Cardon L, Neves T, Bártolo PJ, Pouzada AS (2008) A study of the ejection forces on moulding inserts obtained by RPT techniques. In: RPD 2008 - International conference on rapid product development, Oliveira de Azeméis, Portugal

  16. Mercado-Colmenero JM, Rubio-Paramio MA, Marquez-Sevillano J d J, Martin-Doñate C (2018) A new method for the automated design of cooling systems in injection molds. Comput Aided Des 104:60–86

    Article  Google Scholar 

  17. Nogueira AA, Martinho PG, Brito AM, Pouzada AS (2013) Studies on the mouldability of structural foams in hybrid moulds. Adv Prod Eng Manag 8(2):134–142

    Google Scholar 

  18. Palma JM (1999) Metal spray tool repair system. The Boeing company, Seattle Wash.: US Patent

  19. Pontes AJ, Queirós M, Bártolo PJ, Pouzada AS (2005) A study on design and performance of hybrid moulds for injection moulding. In: ICIT 2005 - 5th International Conference of Industrial Tools, Bled, Slovenia

  20. Pouzada AS (2009) Hybrid moulds: a case of integration of alternative materials and rapid prototyping for tooling. Virtual Phys Prototyp 4(4):195–202

    Article  Google Scholar 

  21. Pouzada AS, Ferreira EC, Pontes AJ (2006) Friction properties on moulding thermoplastics. Polym Test 25:1017–1023

    Article  Google Scholar 

  22. Ribeiro AR Jr, Hopkinson N, Ahrens CH (2004) Thermal effects on stereolithography tools during injection moulding. Rapid Prototyp J 10(3):176–180

    Article  Google Scholar 

  23. Sabino-Netto AC (2008) Desenvolvimento e avaliação de compósito de resina epóxi reforçado com fibras de aço na fabricação de blocos moldantes para moldagem por injeção. Universidade Federal de Santa Catarina, Florianópolis, Tese de Doutorado

    Google Scholar 

  24. Sabino-Netto AC, Salmoria GV, Ahrens CH, Pouzada AS (2008) Friction properties of steel fibre reinforced epoxy composites used in moulding blocks of hybrid moulds. Adv Mater Forum IV 587-588:217–221

    Article  Google Scholar 

  25. Saurkar S, Malloy RA, McCarthy S (2005) Rapid tooling: a study of different cooling techniques for mold inserts used in the direct aim (ACES injection molding) process. In: Proceedings ANTEC 2005 International Conference, Boston, USA

  26. Shojaefard MH, Goudarzi K (2008) The numerical estimation of thermal contact resistance in contacting surfaces. Am J Appl Sci 5(11):1566–1571

    Article  Google Scholar 

  27. Silva EC, Sampaio AM, Pontes AJ (2018) Thermal performance of additive manufacturing in hybrid moulds. In: PMI 2018 - International conference on polymers and moulds innovations, Guimarães, Portugal

Download references

Author information

Authors and Affiliations

  1. CDRSP, School of Technology and Management, Polytechnic of Leiria, Leiria, Portugal

    Pedro Gonçalves Martinho

  2. Institute for Polymers and Composites, University of Minho, Guimarães, Portugal

    António Sérgio Pouzada

Authors
  1. Pedro Gonçalves Martinho
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. António Sérgio Pouzada
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Not applicable

Corresponding author

Correspondence to Pedro Gonçalves Martinho.

Ethics declarations

Conflict of interest

The authors declare that they have no conflict of interest.

Code availability

Not applicable

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Martinho, P.G., Pouzada, A.S. Alternative materials in moulding elements of hybrid moulds: structural integrity and tribological aspects. Int J Adv Manuf Technol 113, 351–363 (2021). https://doi.org/10.1007/s00170-021-06630-5

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-021-06630-5

Keywords

Search

Navigation