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Related Concept Videos

Plastic Deformations01:14

Plastic Deformations

It is essential to understand how structural members behave under plastic deformation when the bending stress exceeds the material's yield strength. This state of deformation permanently alters the shape of the member, in contrast to the linear elastic behavior observed before yielding. The strain at any point in the member is expressed in terms of maximum strain. Notably, the neutral axis, which coincides with the centroid during elastic bending, shifts away from the centroid under plastic...
Plastic Deformations01:19

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Plastic deformation represents a fundamental concept in materials science, which explains the irreversible change in the shape of a material when it experiences stress beyond its elastic capability. This phenomenon is important in structural engineering, especially in designing and analyzing cantilever beams—structures that are securely fixed at one end and bear loads at the opposite end. When these beams are subjected to loads within their elastic range, they will return to their original...
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Injection Moulding into 3D-Printed Plastic Inserts Produced Using the Multi Jet Fusion Method.

Martin Habrman1, Zdeněk Chval1, Karel Ráž1

  • 1Faculty of Mechanical Engineering, Regional Technological Institute, University of West Bohemia, Univerzitni 8, 306 14 Plzen, Czech Republic.

Materials (Basel, Switzerland)
|July 14, 2023
PubMed
Summary

3D printing offers a cost-effective alternative for creating injection moulds. This study compares injection moulding using 3D-printed plastic inserts versus traditional aluminium, revealing distinct differences in process and outcomes.

Keywords:
3D printing3D-printed plastic injection-moulded insertinjection mouldingmulti jet fusion (MJF)

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Area of Science:

  • Materials Science
  • Manufacturing Engineering
  • Additive Manufacturing

Background:

  • Conventional injection moulds made from steel or aluminium incur significant production costs.
  • Additive manufacturing (3D printing) presents a potential solution for reducing injection mould costs.
  • Exploring 3D-printed plastic for injection mould inserts is crucial for cost-effective manufacturing.

Purpose of the Study:

  • To investigate and compare the process of injection moulding using a 3D-printed plastic mould insert against a conventional aluminium insert.
  • To analyze the differences in technological conditions and outcomes when using plastic versus aluminium mould inserts.
  • To examine the interface between the injection-moulded part and the plastic insert at a microscopic level.

Main Methods:

  • A custom injection mould was designed with interchangeable inserts: one 3D-printed plastic and one aluminium.
  • The plastic injection insert was fabricated using HP Multi Jet Fusion 4200 3D printing technology.
  • Both inserts were subjected to identical injection moulding conditions for comparative analysis, followed by electron microscopy of the interface.

Main Results:

  • Significant differences were observed in the injection moulding process and the resulting moulded parts when using plastic versus aluminium inserts.
  • Technological conditions varied between the plastic and aluminium inserts, influencing the moulding outcomes.
  • Electron microscopy revealed distinct interfacial characteristics between the moulded part and the plastic insert compared to the aluminium insert.

Conclusions:

  • 3D-printed plastic mould inserts provide a viable, cost-saving alternative to traditional materials like aluminium for specific injection moulding applications.
  • The differences in material properties between 3D-printed plastic and aluminium lead to variations in processing parameters and final part characteristics.
  • Microscopic analysis confirms the unique interaction at the interface when employing 3D-printed plastic mould components.