Design, development and evaluation of 3D mold inserts using a rapid prototyping technique and powder-sintering process

Abstract

In this research work, attempts have been made to design, develop and evaluate the performance of mould inserts for injection moulding by using a powder-sintering process. Maraging steel powder, sintering aid and binder are materials used in this proposed development process. Attempts have been made to perform in-depth studies and to apply the powder-sintering process, to eventually produce the final sintered components. In addition, an analysis of the dimensional accuracy of the respective stereolithography master models and an analysis of the sintered specimens during various stages of powder-sintering process have been carried out. The intelligent manufacturing systems (IMS) test part with minor modifications has been used in the evaluation of dimensional accuracy, tolerances, distortion and volumetric variations. The main reason for using this unique geometry is the suitability of its design for injection-moulding processes and tooling.