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Validation of Filament Materials for Injection Moulding 3D-Printed Inserts Using Temperature and Cavity Pressure

Daniele Battegazzore1, Alex Anghilieri2, Giorgio Nava2

  • 1Dipartimento di Scienza Applicata e Tecnologia, Politecnico di Torino, Alessandria Site, V.le Teresa Michel 5, 15121 Alessandria, Italy.

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Summary
This summary is machine-generated.

This study shows that combining material testing with computer-aided engineering (CAE) simulation effectively screens additive manufacturing filaments for injection moulding (IM) inserts. Most tested materials proved suitable for IM applications, supporting rapid tooling.

Keywords:
injection moldingmaterial extrusion 3D printingmold insertssimulationthermal conductivitythermo-mechanical properties

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Area of Science:

  • Materials Science
  • Manufacturing Engineering
  • Additive Manufacturing

Background:

  • Additive manufacturing (AM) offers customization for injection moulding (IM) inserts.
  • Challenges include operating temperature and mechanical resistance of AM materials.
  • A systematic screening methodology is needed to evaluate material suitability for IM.

Purpose of the Study:

  • To develop and validate a methodology for screening Material Extrusion (MEX) filaments for IM insert applications.
  • To assess the suitability of ten commercial MEX filaments under IM conditions.
  • To evaluate the effectiveness of combining material characterization with CAE simulation.

Main Methods:

  • Ten commercial MEX filaments were used to produce test samples.
  • Moldex3D software simulated the IM process for two thermoplastics (LDPE and PP).
  • Experimental material characterization and thermal imaging validated simulation results.

Main Results:

  • Nine out of ten MEX materials were suitable for IM with LDPE; five were suitable with PP.
  • Six insert solutions required post-processing for assembly; three did not.
  • All materials withstood 10 injection cycles, and simulation temperature predictions were validated.

Conclusions:

  • A combined approach of material characterization and CAE simulation is effective for selecting MEX filaments for IM inserts.
  • This strategy supports rapid tooling applications in niche production.
  • The methodology provides a low-cost and efficient screening process.