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<p>The use of molds in industry is fundamental for the transformation of materials used to produce goods. The industry's competitiveness depends on manufacturing these tools in less time, at a lower cost, and with a higher quality. This article explores the use of 7075 aluminum as a material for thermoplastic injection mold cavities. To this end, two technology demonstrator molds were developed and analyzed: one made of 7075 aluminum and the other made of traditional AISI P20 tool steel. Since it can be machined with lower cutting forces and higher cutting speeds, aluminum cavities reduced manufacturing time by 40% and, consequently, reduced mold costs. In the injection molding process, the advantages expected from the use of aluminum alloy proved to be correct for the chosen geometry. Regarding the cooling time, the results obtained in this research showed a 27.7% reduction in injection time in the cycle, which resulted in a reduction of the manufacturing cost of the injected parts. It is important to highlight that there is a potential to reduce the injection cycle time of the aluminum mold. The aluminum mold showed lower temperature gradients during the cycle but higher extraction forces. However, thermomechanical analyses showed that using aluminum molds might be limited when injecting parts that need high packing pressures, as this is the main reason for the stresses on the mold during injection. Shortly, depending on the geometry and material to be injected, the aluminum mold may be more interesting than the steel mold, even for high production.</p>

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Development of aluminum injection mold for large-scale production of plastic parts

  • 期刊论文

  • 发表日期：

    2025年6月27日

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  • Pedro Guilherme Carvalho de Souza Marconi,
  • Valter Estevão Beal,
  • Armando Sá Ribeiro Junior,
  • Cristiano Vasconcellos Ferreira,
  • Luciano Pisanu

摘要

The use of molds in industry is fundamental for the transformation of materials used to produce goods. The industry's competitiveness depends on manufacturing these tools in less time, at a lower cost, and with a higher quality. This article explores the use of 7075 aluminum as a material for thermoplastic injection mold cavities. To this end, two technology demonstrator molds were developed and analyzed: one made of 7075 aluminum and the other made of traditional AISI P20 tool steel. Since it can be machined with lower cutting forces and higher cutting speeds, aluminum cavities reduced manufacturing time by 40% and, consequently, reduced mold costs. In the injection molding process, the advantages expected from the use of aluminum alloy proved to be correct for the chosen geometry. Regarding the cooling time, the results obtained in this research showed a 27.7% reduction in injection time in the cycle, which resulted in a reduction of the manufacturing cost of the injected parts. It is important to highlight that there is a potential to reduce the injection cycle time of the aluminum mold. The aluminum mold showed lower temperature gradients during the cycle but higher extraction forces. However, thermomechanical analyses showed that using aluminum molds might be limited when injecting parts that need high packing pressures, as this is the main reason for the stresses on the mold during injection. Shortly, depending on the geometry and material to be injected, the aluminum mold may be more interesting than the steel mold, even for high production.