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Personalized Mass Production by Hybridization of Additive Manufacturing and Injection Molding

The new trend in the composites industry, as dictated by Industry 4.0, is the personalization of mass production to match every customer’s individual needs. Such synergy can be achieved when several traditional manufacturing techniques are combined within the production of a single part. One of the...

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Autores principales: Rajamani, Praveen Kannan, Ageyeva, Tatyana, Kovács, József Gábor
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2021
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC7835752/
https://www.ncbi.nlm.nih.gov/pubmed/33478157
http://dx.doi.org/10.3390/polym13020309
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author Rajamani, Praveen Kannan
Ageyeva, Tatyana
Kovács, József Gábor
author_facet Rajamani, Praveen Kannan
Ageyeva, Tatyana
Kovács, József Gábor
author_sort Rajamani, Praveen Kannan
collection PubMed
description The new trend in the composites industry, as dictated by Industry 4.0, is the personalization of mass production to match every customer’s individual needs. Such synergy can be achieved when several traditional manufacturing techniques are combined within the production of a single part. One of the most promising combinations is additive manufacturing (AM) with injection molding. AM offers higher production freedom in comparison with traditional techniques. As a result, even very sophisticated geometries can be manufactured by AM at a reasonable price. The bottleneck of AM is the production rate, which is several orders of magnitude slower than that of traditional plastic mass production technologies. On the other hand, injection molding is a manufacturing technique for high-volume production with little possibility of customization. The customization of injection-molded parts is usually very expensive and time-consuming. In this research, we offered a solution for the individualization of mass production, which includes 3D printing a baseplate with the subsequent overmolding of a rib element on it. We examined the bonding between the additive-manufactured component and the injection-molded component. As bonding strength between the coupled elements is significantly lower than the strength of the material, we proposed five strategies to improve bonding strength. The strategies are optimizing the printing parameters to obtain high surface roughness, creating an infill density in fused filament fabrication (FFF) parts, creating local infill density, creating microstructures, and incorporating fibers into the bonding area. We observed that the two most effective methods to increase bonding strength are the creation of local infill density and the creation of a microstructure at the contact area of FFF-printed and injection-molded elements. This increase was attributed to the porous structures that both methods created. The melt during injection molding flowed into these pores and formed micro-mechanical interlocking.
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spelling pubmed-78357522021-01-27 Personalized Mass Production by Hybridization of Additive Manufacturing and Injection Molding Rajamani, Praveen Kannan Ageyeva, Tatyana Kovács, József Gábor Polymers (Basel) Article The new trend in the composites industry, as dictated by Industry 4.0, is the personalization of mass production to match every customer’s individual needs. Such synergy can be achieved when several traditional manufacturing techniques are combined within the production of a single part. One of the most promising combinations is additive manufacturing (AM) with injection molding. AM offers higher production freedom in comparison with traditional techniques. As a result, even very sophisticated geometries can be manufactured by AM at a reasonable price. The bottleneck of AM is the production rate, which is several orders of magnitude slower than that of traditional plastic mass production technologies. On the other hand, injection molding is a manufacturing technique for high-volume production with little possibility of customization. The customization of injection-molded parts is usually very expensive and time-consuming. In this research, we offered a solution for the individualization of mass production, which includes 3D printing a baseplate with the subsequent overmolding of a rib element on it. We examined the bonding between the additive-manufactured component and the injection-molded component. As bonding strength between the coupled elements is significantly lower than the strength of the material, we proposed five strategies to improve bonding strength. The strategies are optimizing the printing parameters to obtain high surface roughness, creating an infill density in fused filament fabrication (FFF) parts, creating local infill density, creating microstructures, and incorporating fibers into the bonding area. We observed that the two most effective methods to increase bonding strength are the creation of local infill density and the creation of a microstructure at the contact area of FFF-printed and injection-molded elements. This increase was attributed to the porous structures that both methods created. The melt during injection molding flowed into these pores and formed micro-mechanical interlocking. MDPI 2021-01-19 /pmc/articles/PMC7835752/ /pubmed/33478157 http://dx.doi.org/10.3390/polym13020309 Text en © 2021 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 (http://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Rajamani, Praveen Kannan
Ageyeva, Tatyana
Kovács, József Gábor
Personalized Mass Production by Hybridization of Additive Manufacturing and Injection Molding
title Personalized Mass Production by Hybridization of Additive Manufacturing and Injection Molding
title_full Personalized Mass Production by Hybridization of Additive Manufacturing and Injection Molding
title_fullStr Personalized Mass Production by Hybridization of Additive Manufacturing and Injection Molding
title_full_unstemmed Personalized Mass Production by Hybridization of Additive Manufacturing and Injection Molding
title_short Personalized Mass Production by Hybridization of Additive Manufacturing and Injection Molding
title_sort personalized mass production by hybridization of additive manufacturing and injection molding
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC7835752/
https://www.ncbi.nlm.nih.gov/pubmed/33478157
http://dx.doi.org/10.3390/polym13020309
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