A Soft Tooling process chain employing Additive Manufacturing for injection molding of a 3D component with micro pillars

The purpose of the research presented in this paper is to investigate the capability of a soft tooling process chain employing Additive Manufacturing (AM) for preproduction of an insert with micro features by injection molding. The Soft Tooling insert was manufactured in a high temperature photopolymer by Digital Light Processing (vat photopolymerization). The mold cavity was formed by two insert halves, by design; both inserts have four angled tines, with micro holes (Ø200 μm, 200 μm deep) on the surface. Injection molding with polyethylene was used with the soft tool inserts to manufacture the final production components. The diameter and height of the pillars that were replicated on the molded components were characterized by means of a 3D profilometer. The influence of the injection molding parameters on the replication was evaluated using a 2-levels DOE of three factors. The uniformity of the pillars are also evaluated regarding the diameter and height.