Loading…

Laser-powder bed fusion molds without post-processing for micro-injection molding of mini/micro-products

The use of additive manufacturing (AM) processes at the micro-scale helps to increase the development of micro-systems, thus enabling shorter tooling development to be exploited for other micro-technologies, such as micro-injection molding (µ-IM). In recent years, these process combinations have sho...

Full description

Saved in:
Bibliographic Details
Published in:International journal of advanced manufacturing technology 2023-07, Vol.127 (1-2), p.677-688
Main Authors: Surace, Rossella, Errico, Vito, Valori, Marcello, Fassi, Irene, Campanelli, Sabina Luisa
Format: Article
Language:English
Subjects:
Citations: Items that this one cites
Online Access:Get full text
Tags: Add Tag
No Tags, Be the first to tag this record!
Description
Summary:The use of additive manufacturing (AM) processes at the micro-scale helps to increase the development of micro-systems, thus enabling shorter tooling development to be exploited for other micro-technologies, such as micro-injection molding (µ-IM). In recent years, these process combinations have shown their capability of providing greater flexibility to micro-technologies and facilitating a high production rate, in particular allowing µ-IM to be economically feasible for low-volume production. Therefore, in order to assess the feasibility of micro-metal AM for µ-IM mold production, a set of mini- and micro-polymeric parts injected by using molds realized via the laser-powder bed fusion (L-PBF) process is discussed in this paper. The molds were manufactured in low-carbon steel and have been characterized and tested experimentally, without any post-process treatment. Two selected geometries, corresponding to a mini dogbone for tensile tests and a flexural hinge with features at the micro-scale, were designed and realized by the µ-IM process. These were replicated in order to assess the accuracy of the whole process. The obtained results of replication accuracy and mechanical tests confirm that the µ-IM process, performed with an L-PBF-made mold insert, is feasible and affordable for micro-production, although great accuracy, especially in mold design, fabrication, and assembly, is required.
ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-023-11585-w