Abstract
The mold-making industry is currently facing several challenges, including new competitors in the market as well as the increasing demand for a low volume of precision moldings. The purpose of this research is to appraise a new formulation of Metal Epoxy Composite (MEC) materials as a mold insert. The fabrication of mold inserts using MEC provided commercial opportunities and an alternative rapid tooling method for injection molding application. It is hypothesized that the addition of filler particles such as brass and copper powders would be able to further increase mold performance such as compression strength and thermal properties, which are essential in the production of plastic parts for the new product development. This study involved four phases, which are epoxy matrix design, material properties characterization, mold design, and finally the fabrication of the mold insert. Epoxy resins filled with brass (EB) and copper (EC) powders were mixed separately into 10 wt% until 30 wt% of the mass composition ratio. Control factors such as degassing time, curing temperature, and mixing time to increase physical and mechanical properties were optimized using the Response Surface Method (RSM). The study provided optimum parameters for mixing epoxy resin with fillers, where the degassing time was found to be the critical factor with 35.91%, followed by curing temperature with 3.53% and mixing time with 2.08%. The mold inserts were fabricated for EB and EC at 30 wt% based on the optimization outcome from RSM and statistical ANOVA results. It was also revealed that the EC mold insert offers better cycle time compared to EB mold insert material.
Highlights
Plastic parts for various applications are produced mainly through the injection molding process under heat and pressure conditions to form the product into the desired shape and size [1,2]
The first phase starts with the investigation on the filler particles which emphasizes the literature review of previous studies on the use of filler particles as metal epoxy composite material
ALWA High Temperature resin M2200 manufactured by ALWA resin systems and porous slabs, Grunau, Germany for tooling applications and irregular-shaped brass and copper filler particles were selected for the purpose of improving the ability of mold inserts with regard to its durability and high thermal conductivity
Summary
Plastic parts for various applications are produced mainly through the injection molding process under heat and pressure conditions to form the product into the desired shape and size [1,2]. Molds for plastic injection molding are usually made of tool steel through the machining process using a CNC (Computer Numerical Control) precision machine [3,4,5]. Toolmakers need to invest in expensive equipment, such as Materials 2021, 14, 665 made of tool steel through the machining process using a CNC (Computer Numerical Control) precision machine [3,4,5]. Toolmakers need to invest in expensive equipment, suCcNhCasmCaNchCinme taocohlisn, eantoEollesc,taron-DElieschtraor-gDeiMschacahrgineeM(EaDchMin),ed(rEilDlinMg),mdarcilhlineg amnadcmhienteroalnogdy meeqturoiplomgeynetq, wuihpimchenhta,vwehhiicghhhflaevxeibhiilgithyffloerxisbmiliatlyl-ftor-msmedailul-mto-bmatecdhiupmrobdautccthiopnroadnducmtionld acnodmmpolndenctomfabproicnaetniotnfa[b6r].icTahtieodnim[6]e.nTsihoenadlimacecnusriaocnyaolfatchceutroaocylinogf athned tfoaoblriincagtiaonndpfraobcreis-s cadteiopnenpdrsocoenssthdeepsternicdtsroeqnutihremstreinctsreoqf uthireefimneanltps roofdthuectfiwnahlicphrordequuctirweshhicihghrepqrueicriessiohnigfhor pcroecmispiolenxfgoreocmometprlyexangdeofimneetrsyurafnadcefifinneissuhrifnagce[7fi]n. Tvahnetaagdevsaonftathgiesstyopf ethoifsmtyoplde aorfemefofilcdieanrcey efinficmieinncimy iinzimnginwimasitzeinagndweansteergayndcoennseurmgypctioonns;uamgiplittiyonto; acguislittoymtoizceuasntodmeaizsee aonf dfleexaisbeiloitfy flteoxicbhialintygetoacnhdainngceorapnodriantecodrepsoirgantecodnecsiegpntsc[o1n4c–e1p6t]s. [T1h4e–1a6d].vTanhteaagdevsaonfttahgiesstyopf tehoisf tmypoled oaf rme oelfdficaierenceyffiicniemnicnyiminizminingiwmaizsitneganwdaestneeargnydceonnesrugmy pcotinosnu;magpitliitoynt;oagcuilsittyomtoizceusatnodmeiazsee aonfdfleeaxsiebioliftyflteoxcibhialintygetoancdhainncgoerpaonrdatiendcoerspigonractoendceepsitgs n[2c,3o,n8]c.eMptasn[u2,f3a,c8t]u. rMeras nhuafvaectsuoruegrhs t htahvee nsooung-chotntvheenntioonn-acol npvroencetisosnfaolrptrooocleisnsgfofarbtroioclaitnigonfawbrhicicahtioinncwluhdiechs RinTclaunddeseRxTplaonredd exalptleorrneadtivaeltmerantaetriivaelsmwaittherfiaaslstewr ditehlivfaesrtye,rindcerleiavseerdy,qiunaclrietya,sreedduqcueadliptyr,odreudcut cdeedveploropdmuecntt dteivmeelo, apnmdecnotmtimpaet,ibalnedwciothmgplaotbiballetrwenitdhsg[l1o0b]a. l trends [10]
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