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When materials are subjected to forces that surpass their yield strength, they undergo a process known as plastic deformation. This results in a permanent alteration or strain in their structure. This concept can be specifically applied to circular shafts, where the deformation leads to a change in its shape. The precise evaluation of this plastic deformation requires understanding the stress distribution within the circular shaft, which is achieved by calculating the maximum shearing stress in...
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Analysing Powder Injection Moulding of a Helix Geometry Using Soft Tooling.

Alberto Basso1, Yang Zhang1, Jacob Kjeldahl Pløger1

  • 1Department of Mechanical Engineering, Technical University of Denmark, 2800 Copenhagen, Denmark.

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Summary

Freeform injection moulding uses 3D printed sacrificial moulds for complex geometries. This study validates the process for stainless steel powder injection, showing good agreement between experimental and numerical results for geometrical precision.

Keywords:
additive manufacturingfreeform injection mouldinglow pressure injection mouldingpowder injection mouldingsimulationsoft tooling

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Area of Science:

  • Materials Science
  • Manufacturing Engineering
  • Additive Manufacturing

Background:

  • Freeform injection moulding utilizes sacrificial 3D printed moulds for enhanced geometrical flexibility.
  • Limited understanding exists regarding sacrificial tooling material behavior with complex geometries in powder injection moulding.

Purpose of the Study:

  • To investigate the feasibility of using 3D printed sacrificial moulds for complex geometries in powder injection moulding.
  • To evaluate the geometrical precision and process behavior of stainless steel powder injection into a helix-shaped sacrificial mould.

Main Methods:

  • Utilized vat photopolymerization additive manufacturing to create a sacrificial helix mould.
  • Injected a stainless steel powder suspension into the mould.
  • Employed computed tomography to quantify geometrical precision before and after injection.
  • Developed a new numerical model incorporating suspension feedstock for process investigation.

Main Results:

  • Demonstrated successful injection moulding into a geometrically challenging 3D printed sacrificial mould.
  • Computed tomography revealed geometrical precision of the mould post-injection.
  • Numerical model results qualitatively agreed with experimental findings, identifying critical areas.

Conclusions:

  • The study highlights a viable pathway for evaluating complex sacrificial inserts in powder injection moulding.
  • Combines experimental validation with numerical modelling to assess freeform injection moulding processes.
  • Advances the understanding of material-suspension interactions in complex-geometry additive manufacturing applications.