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<p>This study presents a systematic procedure for evaluating the feasibility of using rapid tooling (RT) for injection molds, particularly those made from polymers. Rapid Tooling, also referred to as soft tooling, involves the use of tools produced through Additive Manufacturing (AM) technologies to enable faster tool fabrication for short-run or pilot production series. The use of RT facilitates the rapid evaluation of injection-molded components and the production of customized series. However, polymer-based tools exhibit limitations when compared to traditional metallic molds, particularly in terms of mechanical strength and thermal performance. Nonetheless, polymer molds manufactured via AM are generally more cost-effective and faster to produce than both AM-based and conventionally manufactured metal molds. This study proposes a systematic methodology aimed at extending the service life of RT polymer molds by incorporating thermomechanical and rheological computational analyses. The proposed approach was experimentally validated through the injection of a polypropylene part using an RT mold made of polyamide 12, produced via the Multi Jet Fusion (MJF) AM process. The results demonstrated the effectiveness of the methodology in identifying optimal injection molding parameters that enhance RT mold longevity while preserving the dimensional and functional quality of the complex injection-molded part.</p>

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Systematic approach for injection mold rapid tooling

  • 期刊论文

  • 发表日期：

    2025年11月22日

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  • Pedro Guilherme Carvalho de Souza Marconi,
  • Valter Estevão Beal,
  • Cristiano Vasconcellos Ferreira,
  • Armando Sá Ribeiro Jr.

摘要

This study presents a systematic procedure for evaluating the feasibility of using rapid tooling (RT) for injection molds, particularly those made from polymers. Rapid Tooling, also referred to as soft tooling, involves the use of tools produced through Additive Manufacturing (AM) technologies to enable faster tool fabrication for short-run or pilot production series. The use of RT facilitates the rapid evaluation of injection-molded components and the production of customized series. However, polymer-based tools exhibit limitations when compared to traditional metallic molds, particularly in terms of mechanical strength and thermal performance. Nonetheless, polymer molds manufactured via AM are generally more cost-effective and faster to produce than both AM-based and conventionally manufactured metal molds. This study proposes a systematic methodology aimed at extending the service life of RT polymer molds by incorporating thermomechanical and rheological computational analyses. The proposed approach was experimentally validated through the injection of a polypropylene part using an RT mold made of polyamide 12, produced via the Multi Jet Fusion (MJF) AM process. The results demonstrated the effectiveness of the methodology in identifying optimal injection molding parameters that enhance RT mold longevity while preserving the dimensional and functional quality of the complex injection-molded part.