As a mainstream manufacturing method, injection molding technology provides thousands of plastic products for all aspects of life and manufacturing. In the past 150 years since its invention, one thing about injection molding has not changed: the demand for molds.Although CNC and3D printingThe intervention of technology makes the mold manufacturing process faster and faster, but the complex mold manufacturing process and technological challenges are always accompanied by around.
Additive Manufacturing Work-3D printingBecause emerging technologies have been widely used in prototype manufacturing, with the development of technology and material advancements, additive manufacturing has been increasingly used in mass direct production, and it has become a partial replacement and coexistence relationship with the injection molding process.
So, for the direct mass production of plastic parts3D printingUnder what circumstances can technology replace the injection molding process?Plastic parts production enterprises pass the production level3D printingWhat are the advantages of technology?For direct production of plastic parts3D printingWhat are the properties of the material?Veteran industrial grade3D printingApplication experts of enterprise 3D Systems, with production-level light curing3D printingThe technical Figure 4 and materials are taken as examples to explain the above problems.
Choice based on cost and efficiency
No solution is perfect, and the choice of process is inseparable from the consideration of economic benefits. When hundreds of thousands of output are required, mold + injection molding is still the preferred choice. Dividing a mold worth tens of thousands of dollars by hundreds of thousands, the cost of the mold will be reduced to a few cents per piece, and the price advantage of injection molding materials will gradually gain advantages as the production volume increases. On the other hand, when the order quantity is less than 2,000 small batch manufacturing, the additive manufacturing digital factory will have a significant advantage. In this case, the cost of each injection molded part may be 10 to 100 times that of additive manufacturing digital production.
Source: 3D Systems
In addition to the actual production cost of traditional injection molded parts, there are other financial factors that need to be considered, such as labor costs and supply chain management: additional labor, materials and CNC processing, testing costs, etc.3D printingDigital production reduces the marginal cost. If the appearance and function of the product are not as expected, it can be modified in CAD at any time and manufactured immediately-without the need to design a new mold.
Source: 3D Systems
In 3D Systems micro-class, Figure 4 3D printingThe technology and the “reasonable cost threshold” of injection molding were analyzed and compared, and the production timeline required by the two processes was analyzed in detail through the production cases of nozzle parts.
Material is the key
all3D printingApplication, especially production level3D printingApplications, all need to rely on3D printingThe properties of the material itself. Through Figure 4 3D printingTechnically manufactured plastic products are closely related to Figure 4® series of new materials.
Source: 3D Systems
3D Systems has conducted comprehensive tests on the latest Figure 4® materials in accordance with ASTM and ISO standards. This series of materials is the core of 3D Systems’ digital manufacturing solutions. 3D Systems provides plastic component manufacturers with a complete data set to appropriately screen the practicality of materials for their applications, so that they can continue to carry out long-term application tests in a timely manner, such as component/component service life testing or higher biocompatibility grade.
In the micro-class, the two most distinctive Figure 4 materials are used as examples to explain the performance of the materials, the feedback from testing customers, and the application scope of the materials.
Figure 4™ PRO-BLK 10
This is a production-grade additive manufacturing material with disruptive thermoplastic mechanical properties and environmental stability, and can be used for the direct production of plastic parts. The material can achieve fast printing speeds of up to 60 mm/hour, and simplifies the post-processing process including a single curing cycle and single solvent cleaning, and achieves excellent throughput.
Source: 3D Systems
It is a high-precision resin-made part with good surface finish, excellent sidewall quality and excellent mechanical properties.
- Environmental stability means that parts can remain consistent in terms of mechanical properties, color, opacity and size for a long time
- Printing speed up to 60 mm/hour, layer thickness 50 µm
- No post-treatment after heat curing, making it a simple and effective method for mold-free production
Figure 4™ HI TEMP 300-AMB
This is an ultra-high temperature resistant plastic suitable for applications requiring high heat resistance. Regardless of whether it is a high-pressure or low-pressure environment, its HDT is above 300 degrees Celsius (HDT values measured under 0.455 and 1.82MPa). This material is very suitable for testing high-temperature components, including HVAC, household appliances, motor housings, hair dryers, etc.
Source: 3D Systems
- HDT over 300˚C
- No post-treatment after heat curing
With the development of materials and equipment, it is becoming more and more mature. Additive manufacturing is adapted to small batch production and the manufacture of components with complex structures, bringing new speed, accuracy, strength and durability to the moldless manufacturing and mass production of various industries, which can only take more time to pass the traditional Obtained by means of injection molding.3D printingIndustrial-grade materials with outstanding technical matching properties can greatly benefit even small factories!
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