Development, Simulation of Temperatures, and Experimentation in Injection Molds Obtained through Additive Manufacturing with Photocurable Polymeric Resins.

Additive manufacturing (AM) is a relatively new option in mold manufacturing for rapid tooling (RT) in injection processes. This paper presents the results of experiments with mold inserts and specimens obtained by stereolithography (SLA), which is a kind of AM. A mold insert obtained by AM and a mold produced by traditional subtractive manufacturing were compared to evaluate the performance of the injected parts. In particular, mechanical tests (in accordance with ASTM D638) and temperature distribution performance tests were carried out. The tensile test results of specimens obtained in a 3D printed mold insert were better (almost 15%) than those produced in the duralumin mold. The simulated temperature distribution closely matched its experimental counterpart-the difference in average temperatures was merely 5.36 °C. These findings support the use of AM in injection molding and RT as an excellent alternative for small and medium-sized production runs in the global injection industry.

Analysis and Advances in Additive Manufacturing as a New Technology to Make Polymer Injection Molds for World-Class Production Systems.

The currently growing demand for metallic and polymeric products has undoubtedly changed the rules of manufacturing, enabling customers to more functionally define their products based on their needs. Nowadays, a new technique for rapid tooling, Additive Manufacturing (AM), can create customized products with more complex geometries and short life cycles (flexibility) in order to keep up with the new variables imposed by the manufacturing environment. In the last two decades, the migration from subtractive manufacturing to AM has materialized such products with reduced costs and cycle times. AM has been recently promoted to develop polymer molds for product manufacturing. This paper reviews the main findings in the literature concerning polymer molds created by AM compared to conventional (metal) molds obtained by subtractive manufacturing. Information about specific topics is scarce or nonexistent, for example, about the characterization of the most commonly injected materials and molds used in this type of technology, their mechanical properties (part and mold), designs for all types of geometries, and costs. These aspects are addressed in this literature review, highlighting the advantages of this alternative manufacturing process, which is considered a desirable technology worldwide.

E-Skin Development and Prototyping via Soft Tooling and Composites with Silicone Rubber and Carbon Nanotubes.

The strategy of embedding conductive materials on polymeric matrices has produced functional and wearable artificial electronic skin prototypes capable of transduction signals, such as pressure, force, humidity, or temperature. However, these prototypes are expensive and cover small areas. This study proposes a more affordable manufacturing strategy for manufacturing conductive layers with 6 × 6 matrix micropatterns of RTV-2 silicone rubber and Single-Walled Carbon Nanotubes (SWCNT). A novel mold with two cavities and two different micropatterns was designed and tested as a proof-of-concept using Low-Force Stereolithography-based additive manufacturing (AM). The effect SWCNT concentrations (3 wt.%, 4 wt.%, and 5 wt.%) on the mechanical properties were characterized by quasi-static axial deformation tests, which allowed them to stretch up to ~160%. The elastomeric soft material's hysteresis energy (Mullin's effect) was fitted using the Ogden-Roxburgh model and the Nelder-Mead algorithm. The assessment showed that the resulting multilayer material exhibits high flexibility and high conductivity (surface resistivity ~7.97 × 104 Ω/sq) and that robust soft tooling can be used for other devices.

Characterization of Soft Tooling Photopolymers and Processes for Micromixing Devices with Variable Cross-Section.

In this paper, we characterized an assortment of photopolymers and stereolithography processes to produce 3D-printed molds and polydimethylsiloxane (PDMS) castings of micromixing devices. Once materials and processes were screened, the validation of the soft tooling approach in microfluidic devices was carried out through a case study. An asymmetric split-and-recombine device with different cross-sections was manufactured and tested under different regime conditions (10 < Re < 70). Mixing performances between 3% and 96% were obtained depending on the flow regime and the pitch-to-depth ratio. The study shows that 3D-printed soft tooling can provide other benefits such as multiple cross-sections and other potential layouts on a single mold.

Bearded capuchin monkeys use joint synergies to stabilize the hammer trajectory while cracking nuts in bipedal stance.

The transition from occasional to obligate bipedalism is a milestone in human evolution. However, because the fossil record is fragmentary and reconstructing behaviour from fossils is difficult, changes in the motor control strategies that accompanied this transition remain unknown. Quadrupedal primates that adopt a bipedal stance while using percussive tools provide a unique reference point to clarify one aspect of this transition, which is maintaining bipedal stance while handling massive objects. We found that while cracking nuts using massive stone hammers, wild bearded capuchin monkeys (Sapajus libidinosus) produce hammer trajectories with highly repeatable spatial profiles. Using an uncontrolled manifold analysis, we show that the monkeys used strong joint synergies to stabilize the hammer trajectory while lifting and lowering heavy hammers. The monkeys stringently controlled the motion of the foot. They controlled the motion of the lower arm and hand rather loosely, showing a greater variability across strikes. Overall, our findings indicate that while standing bipedally to lift and lower massive hammers, an arboreal quadrupedal primate must control motion in the joints of the lower body more stringently than motion in the joints of the upper body. Similar changes in the structure of motor variability required to accomplish this goal could have accompanied the evolutionary transition from occasional to obligate bipedalism in ancestral hominins.