Auslegung und Charakterisierung additiv gefertigter Formeinsätze für Spritzgießwerkzeuge

In the course of this dissertation, the additive manufacturing of mould inserts made of polymer materials for small series production and the additive manufacturing of mould inserts made of metal materials to increase the temperature control quality were investigated. Step by step the injection moulding process chain was proceeded and analysed. At first, the application of additive manufactured mould inserts made of polymer materials was observed. The thermal behaviour during injection moulding, the effective thermal diffusivity for estimating cooling times, the durability, the resulting morphology and the mechanical behaviour of the injection moulded plastic components were analysed. Mould inserts which were produced with the methods Stereolithography (SLA), Selective Laser Sintering (SLS), Fused Filament Fabrication (FFF) and conventional milling (benchmark) were examined. In a second topic area, different tempering channel cross-sections were first evaluated with respect to their tempering quality and then an injection mould was produced with a selected tempering concept. In the course of the design process, a defined sequence for the efficient design of cooling channels was created, in which the thermal and mechanical design steps were considered in combination.