Rajamani Praveen Kannan, Ageyeva Tatyana, Kovács József Gábor
Department of Polymer Engineering, Faculty of Mechanical Engineering, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, Hungary.
MTA-BME Lendület Lightweight Polymer Composites Research Group, Műegyetem rkp. 3., H-1111 Budapest, Hungary.
Polymers (Basel). 2021 Jan 19;13(2):309. doi: 10.3390/polym13020309.
The new trend in the composites industry, as dictated by Industry 4.0, is the personalization of mass production to match every customer's individual needs. Such synergy can be achieved when several traditional manufacturing techniques are combined within the production of a single part. One of the most promising combinations is additive manufacturing (AM) with injection molding. AM offers higher production freedom in comparison with traditional techniques. As a result, even very sophisticated geometries can be manufactured by AM at a reasonable price. The bottleneck of AM is the production rate, which is several orders of magnitude slower than that of traditional plastic mass production technologies. On the other hand, injection molding is a manufacturing technique for high-volume production with little possibility of customization. The customization of injection-molded parts is usually very expensive and time-consuming. In this research, we offered a solution for the individualization of mass production, which includes 3D printing a baseplate with the subsequent overmolding of a rib element on it. We examined the bonding between the additive-manufactured component and the injection-molded component. As bonding strength between the coupled elements is significantly lower than the strength of the material, we proposed five strategies to improve bonding strength. The strategies are optimizing the printing parameters to obtain high surface roughness, creating an infill density in fused filament fabrication (FFF) parts, creating local infill density, creating microstructures, and incorporating fibers into the bonding area. We observed that the two most effective methods to increase bonding strength are the creation of local infill density and the creation of a microstructure at the contact area of FFF-printed and injection-molded elements. This increase was attributed to the porous structures that both methods created. The melt during injection molding flowed into these pores and formed micro-mechanical interlocking.
在工业4.0的推动下，复合材料行业的新趋势是大规模生产的个性化，以满足每个客户的个性化需求。当在单个零件的生产过程中结合多种传统制造技术时，就能实现这种协同效应。最有前景的组合之一是增材制造（AM）与注塑成型。与传统技术相比，增材制造提供了更高的生产自由度。因此，即使是非常复杂的几何形状也可以通过增材制造以合理的价格生产出来。增材制造的瓶颈在于生产率，它比传统塑料大规模生产技术慢几个数量级。另一方面，注塑成型是一种用于大批量生产的制造技术，几乎没有定制的可能性。注塑零件的定制通常非常昂贵且耗时。在本研究中，我们提供了一种大规模生产个性化的解决方案，包括3D打印一个基板，随后在其上包覆成型一个肋状元件。我们研究了增材制造部件与注塑成型部件之间的粘结情况。由于耦合元件之间的粘结强度明显低于材料强度，我们提出了五种提高粘结强度的策略。这些策略包括优化打印参数以获得高表面粗糙度、在熔融长丝制造（FFF）零件中创建填充密度、创建局部填充密度、创建微观结构以及在粘结区域加入纤维。我们观察到，提高粘结强度最有效的两种方法是在FFF打印和注塑成型元件的接触区域创建局部填充密度和创建微观结构。这种提高归因于这两种方法所创建的多孔结构。注塑成型过程中的熔体流入这些孔隙并形成微机械联锁。
