Evaluation of Rapid Prototyped Injection Molding Inserts Using Simulation Moldflow

Rapid prototyping is increasingly being used in the production of injection molding inserts. This technology enables for much lower lead times in prototype and low-volume production. However, the thermal and structural properties of prototyped inserts are different than those of conventional machined inserts. The focus of this class is to use Simulation Moldflow Insight software to evaluate the thermal and mechanical behavior of rapid prototyped injection molding inserts. We will look at 3 sets of inserts that were analyzed using different manufacturing techniques and materials, which included selective laser sintered (SLS) bronze, PolyJet ABS-like material, and conventional machined stainless steel. Molding trials were performed on the inserts, as were computer simulations. The experimental and simulated results were compared for the thermal gradient, structural performance, part warpage, and part shrinkage.