Multi-metal additive manufacturing process chain for optical quality mold generation

F.G. Biondani*, G. Bissacco, S. Mohanty, P. T. Tang, Hans Nørgaard Hansen

*Corresponding author for this work

Research output: Contribution to journalJournal articleResearchpeer-review

Abstract

This paper introduces an innovative process chain for the generation of mold elements based on multi-metal additive manufacturing. Starting from an indirect tooling approach for the fabrication of a mold master with optical surface quality, three different additive processes, namely electroforming, thermal spraying and selective laser melting (SLM), are combined to manufacture a test mold element. In order to maintain the targeted optical quality of the mold surface, SLM process parameters optimization has been carried out through numerical simulations. The approach is experimentally verified by generating prototype mold inserts and validated in injection molding trials, showing no signs of degradation of the mold insert after 1000 injection molding cycles.
Original languageEnglish
Article number116451
JournalJournal of Materials Processing Technology
Volume277
Number of pages6
ISSN0924-0136
DOIs
Publication statusPublished - 2020

Keywords

  • Additive manufacturing
  • Process chain
  • Multi-material

Cite this

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title = "Multi-metal additive manufacturing process chain for optical quality mold generation",
abstract = "This paper introduces an innovative process chain for the generation of mold elements based on multi-metal additive manufacturing. Starting from an indirect tooling approach for the fabrication of a mold master with optical surface quality, three different additive processes, namely electroforming, thermal spraying and selective laser melting (SLM), are combined to manufacture a test mold element. In order to maintain the targeted optical quality of the mold surface, SLM process parameters optimization has been carried out through numerical simulations. The approach is experimentally verified by generating prototype mold inserts and validated in injection molding trials, showing no signs of degradation of the mold insert after 1000 injection molding cycles.",
keywords = "Additive manufacturing, Process chain, Multi-material",
author = "F.G. Biondani and G. Bissacco and S. Mohanty and Tang, {P. T.} and Hansen, {Hans N{\o}rgaard}",
year = "2020",
doi = "10.1016/j.jmatprotec.2019.116451",
language = "English",
volume = "277",
journal = "Journal of Materials Processing Technology",
issn = "0924-0136",
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}

Multi-metal additive manufacturing process chain for optical quality mold generation. / Biondani, F.G.; Bissacco, G.; Mohanty, S.; Tang, P. T.; Hansen, Hans Nørgaard.

In: Journal of Materials Processing Technology, Vol. 277, 116451, 2020.

Research output: Contribution to journalJournal articleResearchpeer-review

TY - JOUR

T1 - Multi-metal additive manufacturing process chain for optical quality mold generation

AU - Biondani, F.G.

AU - Bissacco, G.

AU - Mohanty, S.

AU - Tang, P. T.

AU - Hansen, Hans Nørgaard

PY - 2020

Y1 - 2020

N2 - This paper introduces an innovative process chain for the generation of mold elements based on multi-metal additive manufacturing. Starting from an indirect tooling approach for the fabrication of a mold master with optical surface quality, three different additive processes, namely electroforming, thermal spraying and selective laser melting (SLM), are combined to manufacture a test mold element. In order to maintain the targeted optical quality of the mold surface, SLM process parameters optimization has been carried out through numerical simulations. The approach is experimentally verified by generating prototype mold inserts and validated in injection molding trials, showing no signs of degradation of the mold insert after 1000 injection molding cycles.

AB - This paper introduces an innovative process chain for the generation of mold elements based on multi-metal additive manufacturing. Starting from an indirect tooling approach for the fabrication of a mold master with optical surface quality, three different additive processes, namely electroforming, thermal spraying and selective laser melting (SLM), are combined to manufacture a test mold element. In order to maintain the targeted optical quality of the mold surface, SLM process parameters optimization has been carried out through numerical simulations. The approach is experimentally verified by generating prototype mold inserts and validated in injection molding trials, showing no signs of degradation of the mold insert after 1000 injection molding cycles.

KW - Additive manufacturing

KW - Process chain

KW - Multi-material

U2 - 10.1016/j.jmatprotec.2019.116451

DO - 10.1016/j.jmatprotec.2019.116451

M3 - Journal article

VL - 277

JO - Journal of Materials Processing Technology

JF - Journal of Materials Processing Technology

SN - 0924-0136

M1 - 116451

ER -