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Title: Metal additive manufacturing of plastic injection molds with conformal cooling channels
Authors: Kanbur, Baris Burak
Zhou, Yi
Shen, Suping
Wong, Kim Hai
Chen, Charles
Shocket, Abe
Duan, Fei
Keywords: Engineering::Mechanical engineering
Issue Date: 2022
Source: Kanbur, B. B., Zhou, Y., Shen, S., Wong, K. H., Chen, C., Shocket, A. & Duan, F. (2022). Metal additive manufacturing of plastic injection molds with conformal cooling channels. Polymers, 14(3), 424-.
Journal: Polymers 
Abstract: Conformal cooling channels (CCCs) are widely used in the plastic injection molding process to improve the product quality and operational performance. Tooling that incorporates CCCs can be fabricated through metal additive manufacturing (MAM). The present work focuses on the MAM of a plastic injection mold insert with different CCC types that are circular, serpentine, and tapered channels with/without body-centered cubic (BCC) lattices. The entire manufacturing process of the mold insert is explained from the design step to the final printing step including the computational thermal & mechanical simulations, performance assessments, and multiobjective optimization. Compared to the traditional channels, conformal cooling channels achieved up to 62.9% better cooling performance with a better thermal uniformity on the mold surface. The optimum mold geometry is decided using the multiobjective optimization procedure according to the multiple objectives of cooling time, temperature non-uniformity, and pressure drop in the channel. Direct Metal Laser Sintering (DMLS) method is used for manufacturing the molds and the quality of the printed molds are analyzed with the X-ray Computed Tomography (X-ray CT) technique. The errors between the design and the printed parameters are less than 5% for the circular and tapered channels while the maximum deviation of the strut diameters of the BCC is 0.06 mm.
ISSN: 2073-4360
DOI: 10.3390/polym14030424
Schools: School of Mechanical and Aerospace Engineering 
Research Centres: Singapore Centre for 3D Printing 
Rights: © 2022 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https:// 4.0/).
Fulltext Permission: open
Fulltext Availability: With Fulltext
Appears in Collections:MAE Journal Articles
SC3DP Journal Articles

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