Novel Coupled Simulation Method and Comprehensive Metrology to Enhance the Application of Prototype Injection Moulds

Injection moulding is the most diverse and dynamically developing polymer processing technology. Conventional injection moulding is economically viable only in large-volume part production. However, there is an ever-growing demand for more customised, low-volume plastic products, which is called mass customization. This need can be served by the hybridisation of injection moulding with additively manufactured, low-volume injection moulds (produced for example from thermoset resins by PolyJet technology). In our work, we elaborated a novel statemonitoring and modelling method to analyse the mechanical and thermal characteristics (strains and temperature distribution) of these polymeric injection mould inserts during operation. The results of the modelling method were successfully validated by the actual injection moulding experiments, proving the adequacy of the modelling method. © 2025 Trans Tech Publications Ltd, All Rights Reserved.