Analysis of an as-built metal additively manufactured tool cavity insert performance and advantages for plastic injection moulding

摘要: Abstract Metal additive manufacturing (MAM) of mould components is associated with cost-intensive post-process finishing operations, which are currently one the main drawbacks preventing wider industrial adoption MAM. This work analyses current possibilities and limitations MAM for plastic injection moulding tool applications, demonstrating opportunity to limit post-processes heat treatment machining insert outer geometry, was only intended ensure assembly in frame. The results focused on evaluating as-built cavity geometrical characteristics dimensional replication performance process. surface texture comparable a roughness that would be alternatively manufactured by electrical discharge (EDM). features replicated moulded samples an average fidelity higher than 95 %, enabling direct production inserts integrated enhanced properties aesthetics. Additional characteristics, such as global dimensions, corner radii, staircase effect selected features, typical products, were examined gather further knowledge process resolution corresponding capabilities IM considerations regards mechanical loading conditions its durability terms expected fatigue lifetime addressed, verifying usability batches at least 2⋅106 cycles. Finally, improvements lead-time reduction costs compared conventional tooling technologies evaluated discussed, confirming potential presented chain tools production.