Influence of thermal ageing on the fracture and lifetime of additively manufactured mold inserts

Abstract Due to the significant technical benefits of additive manufacturing (AM), its application has grown considerably in recent years. In this respect, the integration of AM in the injection molding (IM) process chain for tooling purposes is an ongoing research topic. In the current study, the design, fabrication and use of a tool inserts for injection molding process fabricated by a vat photopolymerisation technique. Since molds during the injection molding process are subjected to cyclic thermal variation, accelerated thermal ageing was applied on the AM mold inserts to emulate the effect of continuous production on the tool lifetime. The additively manufactured mold inserts were exposed to thermal cycling loading in the range between room temperature up to 100 °C, and then, they were used in the actual injection molding process. According to the obtained results, effects of thermal ageing on behavior of the mold inserts are demonstrated. Moreover, fractographic analysis is performed on the fractured surfaces to determine crack initiation and propagation on the mold inserts. The current study provides insight about ageing and fracture of IM mold inserts produced by vat photopolymerisation , and these results can be used for the development of computational models, future material design and load-carrying capabilities of additively manufactured mold inserts to expand the use of AM for tooling purposes.