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A Soft Tooling Process Chain for Injection Molding of a 3D Component with Micro Pillars

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Study on hybrid 3D printing and milling process for customized polyether-ether-ketone components.

Haoyi Sun¹, Xiang Cheng¹, Yuanyong Liu¹

¹School of Mechanical Engineering, Shandong University of Technology, Zibo, China.

Proceedings of the Institution of Mechanical Engineers. Part H, Journal of Engineering in Medicine

|October 9, 2024

Summary

This study introduces a hybrid 3D printing and milling process for efficient Polyether-ether-ketone (PEEK) component manufacturing. The novel approach significantly improves surface finish, dimensional accuracy, and material efficiency while enhancing shear strength.

Keywords:

3D printing Hybrid manufacturing PEEK fused deposition manufacturing milling process planning

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Area of Science:

Materials Science
Manufacturing Engineering
Additive Manufacturing

Background:

Polyether-ether-ketone (PEEK) is a high-performance polymer with excellent mechanical properties and biocompatibility.
Customized manufacturing of complex PEEK components faces challenges in achieving high quality and efficiency.

Purpose of the Study:

To investigate an efficient and high-quality customized manufacturing method for PEEK components.
To develop and validate a hybrid 3D printing and milling process.

Main Methods:

Selection and verification of an alternating hybrid process.
Development of automated procedures for the hybrid process.
Proposal of the exchange principle of avoiding interference (EPAI) algorithm for model segmentation.
Implementation of an additive and subtractive hybrid manufacturing (ASHM) data processing procedure using Python.

Main Results:

The hybrid manufacturing process successfully fabricated parts with complex internal features.
Surface roughness (Ra) reduced by 75.5%, dimensional error (L) by 85.2%.
Shear strength (τ) increased by 14.1%, and material consumption reduced by 48.7% compared to conventional milling.

Conclusions:

The developed hybrid 3D printing and milling process is feasible and effective for PEEK component fabrication.
The ASHM procedure, incorporating the EPAI algorithm, enhances precision and efficiency.
This approach offers significant improvements in part quality and material savings.