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ADDfoam
Application of additively manufactured mold inserts microcellular injection molding
Project duration
From: 01.04.2021 To: 30.09.2023Description
The ADDfoam research project aims to evaluate the use of additively manufactured mold inserts for microcellular injection molding. The central questions in the project were the evaluation of the dimensional accuracy and long-term stability of the additively manufactured inserts, as well as the assessment of the surface quality of the foamed components due to the changed thermal conductivity at the mold insert/ injection molded component interface and through the implementation of surface structures in the cavity.
The report identifies challenges in practical implementation and describes the implemented solution strategies. By transferring the process technology from compact injection molding to foam injection molding, the service life of the inserts has been improved by a factor of 8. Reproducibility in small series production is guaranteed. At the same time, the foamed components have a high surface quality, so that applications as visible components are conceivable. The use of thermography for continuous process monitoring makes it possible to evaluate the cooling behavior of the printed inserts cycle by cycle and depending on the set process parameters. The integration of cooling channels and external air cooling are measures that should be taken into account when designing the process in order to optimize economic aspects such as the service life of the inserts, surface quality and cycle time.
The findings from this project greatly increase the competitiveness of companies, especially SMEs, and promote the implementation of lightweight construction strategies and approaches for companies to be able to place products on the market more quickly and respond individually to customer inquiries.Contact person:
