Rapid tooling development for low volume injection molding of cosmetic compacts

Rapid tooling development for low volume injection molding of cosmetic compacts

VELLA Andrea, ROCHMAN Arif, VELLA Pierre

Abstract. This study aimed to explore the capability of different additive manufacturing (AM) or 3D printing technologies to rapidly manufacture mold inserts for injection molding as well as to evaluate the performance of the printed mold inserts and the quality of the injection molded parts. Fused filament fabrication (FFF), stereolithography (SLA), and multi-jet fusion (MJF) 3D printing technologies were used to produce the mold inserts, whereas a cosmetic compact base was selected as the case study part. The results obtained show that it is possible to use the mentioned technologies to manufacture tool inserts for rapid prototyping or low volume production of cosmetic compact bases using injection molding. When using the FFF mold inserts, the cosmetic compact bases produced were not of the best quality and surface finish but still acceptable for prototyping purposes only. The vertically printed SLA mold inserts as well as the MJF mold inserts produced cosmetic compact bases with no flashes and the best surface finish. The MJF mold inserts had excellent thermal properties so that apart from HDPE, a higher melting temperature ABS was also successfully molded. Also using the MJF mold inserts, the highest production number of 80 cosmetic compact bases of a good quality could be achieved.

Keywords
Additive Manufacturing, 3D Printing, Rapid Tooling, Rapid Prototyping, Injection Molding

Published online 4/19/2023, 10 pages
Copyright © 2023 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: VELLA Andrea, ROCHMAN Arif, VELLA Pierre, Rapid tooling development for low volume injection molding of cosmetic compacts, Materials Research Proceedings, Vol. 28, pp 207-216, 2023

DOI: https://doi.org/10.21741/9781644902479-23

The article was published as article 23 of the book Material Forming

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

References
[1] G.N. Levy, R. Schindel, J.P. Kruth, Rapid Manufacturing and Rapid Tooling with Layer Manufacturing (LM) Technologies, State of the Art and Future Perspectives, CIRP Annals – Manuf. Technol. 52 (2003) 589-609. https://doi.org/10.1016/S0007-8506(07)60206-6
[2] S. Mellor, L. Hao, D. Zhang, Additive manufacturing: A framework for implementation, Int. J. Prod. Economics 149 (2014) 194-201. https://doi.org/10.1016/j.ijpe.2013.07.008
[3] P.D. Hilton, P.F. Jacobs, Rapid Tooling Technologies and Industrial Applications, Marcel Dekker, New York, 2000.
[4] S.O. Onuh, Y.Y. Yusuf, Rapid Prototyping Technology: Applications and Benefits for Rapid Product Development, J. Intell. Manuf. 10 (1999) 301-311. https://doi.org/10.1023/A:1008956126775
[5] R. Noorani, Rapid Prototyping: Principles and Applications: Hoboken, N.J Wiley, 2005
[6] J. Pomager. (2015, 2nd November 2015). 3D-Printed Injection Moulding: The Future of Rapid Prototyping? [Online]. Available: https://www.meddeviceonline.com/doc/3d-printed-injection-molding-the-future-of-rapid-prototyping-0001 (accessed: 30 January 2023).
[7] L. Zonder, N. Sella. (2014, 4th November 2015). Stratasys – Persision Prototyping: The Role of 3D Printed Molds in the Injection Molding Industry. [Online]. Available: http://www.stratasys.com/resources/~/media/B828788EF394436DB11BEB5209B2D22C.pdf (accessed: 30 January 2023).
[8] A. Gebhardt, Understanding Additive Manufacturing: Rapid Prototyping Rapid Tooling Rapid Manufacturing: Hanser Publishers, Munich, 2011. https://doi.org/10.3139/9783446431621.fm
[9] C.K. Chua, K.H. Hong, S.L. Ho, Rapid tooling technology. Part 1. A comparative study, Int. J. Adv. Manuf. Technol. 15 (2013) 604-608. https://doi.org/10.1007/s001700050108
[10] C.K. Chua, K.F. Leong, C.S. Lim, Rapid Prototyping Principles and Applications Third Edidtion: World Scientific Pub Co Inc, 2010. https://doi.org/10.1142/6665
[11] D.O. Kazmer, Injection Mold Design Engineering: Hanser Publishers, Munich, 2007. https://doi.org/10.3139/9783446434196.fm
[12] G. Menges, W. Michaeli, P. Mohren, How to Make Injection Molds vol. Third Edition: Hanser Publishers, Munich, 2001. https://doi.org/10.3139/9783446401808.fm