Paper Titles
Prediction of Temperature and Moisture Concentration in Autoclave-Cured Epoxy Resin Using Physics-Informed Neural Networks
p.75
Meshless Transient Thermal Modeling of Polymer Composite Curing with Exothermic Heat Generation
p.87
Material Characterization and Constitutive Modeling of PMMA for the Numerical Simulation of Vacuum Forming Process
p.95
Analysis of Large Deformation Characteristics and Formability of PMMA
p.103
From Deposition Sequence to Mechanical Response: A Macroscale Process Simulation of Material Extrusion
p.111
Bio-Composites for Additive Manufacturing Study of the Mechanical Properties
p.125
Multi-Objective Optimization of Injection-Molded Components for Defect Reduction and Warpage Minimization
p.133
Determination of Gelation Zone Position in Reactive Thermoplastic Pultrusion by Analysis of Heating Power Consumption
p.147
Thermal Transient Modelling and Experimental Validation of Hybrid Polymer-Steel Moulds for Micro-Injection Moulding
p.157

Thermal Transient Modelling and Experimental Validation of Hybrid Polymer-Steel Moulds for Micro-Injection Moulding

Article Preview
View Pdf By email

Abstract:

Efficient thermal management is a key factor in improving the sustainability and productivity of injection moulding processes, particularly at the micro-scale where thermal transients strongly affect part quality and cycle stability. This work investigates the thermal behaviour of hybrid moulds composed of polymeric support plates manufactured in Precision Resin V01 and stainless-steel inserts manufactured by additive manufacturing. An experimental campaign was carried out on a micro-injection moulding machine to characterize the intrinsic thermal response of the mould under uncooled conditions. Temperatures were monitored through embedded thermocouples and used to develop and calibrate a three-dimensional transient numerical model in COMSOL Multiphysics. Particular attention was devoted to the identification and calibration of heat transfer coefficients at the injection and extraction interfaces, which were found to play a dominant role in governing insert temperature evolution. The calibrated model accurately reproduces the experimental thermal transients, with deviations below 10%, demonstrating its reliability as a predictive tool for analysing mould thermal behaviour and supporting early-stage design and process optimization. The results highlight the advantages of hybrid architectures in promoting thermal stability and provide a robust methodology for modelling heat exchange in unconventional mould configurations.

You have full access to the following eBook
Polymer Processing and Thermomechanical Properties Read eBook

Info:

Periodical:

Defect and Diffusion Forum (Volume 451)

Pages:

157-167

DOI:

https://doi.org/10.4028/p-rD7QdB

Citation:

Cite this paper

Online since:

April 2026

Authors:

Giulia Zaniboni*, Vito Basile, Riccardo Pelaccia, Rossella Surace, Keltoum Oubellaouch, Francesco Modica, Leonardo Orazi, Giovanna Rotella, Luigino Filice, Irene Fassi

Keywords:

Additive Manufacturing, Hybrid Moulds, Injection Moulding, Thermal Management

Export:

RIS, BibTeX

Permissions:

Creative Commons CC BY 4.0

Share:

Citation:

* - Corresponding Author

References

[1] H. Fu et al., «Overview of Injection Moulding Technology for Processing Polymers and Their Composites», ES Mater. Manuf., vol. Volume 8 (June 2020), fasc. 20, p.3–23, mag. 2020.

Google Scholar

[2] C. Van Emburg, H. Chen, S. Pilla, G. Li, e M. Carbajales-Dale, «Quantifying energy consumption variability in injection moulding: A meta-regression analysis», Resour. Conserv. Recycl., vol. 227, p.108730, mar. 2026.

DOI: 10.1016/j.resconrec.2025.108730

Google Scholar

[3] Y. Kanematsu, H. Noguchi, T. Semba, H. Yano, e Y. Kikuchi, «Life Cycle Assessment of Automobile Parts Made of Cellulose Nanofiber-Reinforced Bio-Polyethylene Using the Pulp Direct Kneading Method», 8 ottobre 2025, ChemRxiv.

DOI: 10.26434/chemrxiv-2025-qhs18

Google Scholar

[4] T. M. T. Uyen, P. S. Minh, e B. C. Thanh, «Application of Cooling Layer and Thin Thickness Between Coolant and Cavity for Mould Temperature Control and Improving Filling Ability of Thin-Wall Injection Moulding Product», Polymers, vol. 17, fasc. 19, p.2658, set. 2025.

DOI: 10.3390/polym17192658

Google Scholar

[5] D. Masato, D. Kazmer, e A. Gruber, «Meta-analysis of thermal contact resistance in injection moulding: A comprehensive literature review and multivariate modeling», Polym. Eng. Sci., vol. 63, fasc. 12, p.3923–3937, 2023.

DOI: 10.1002/pen.26496

Google Scholar

[6] M. Pagac et al., «A Review of Vat Photopolymerization Technology: Materials, Applications, Challenges, and Future Trends of 3D Printing», Polymers, vol. 13, fasc. 4, p.598, feb. 2021.

DOI: 10.3390/polym13040598

Google Scholar

[7] J. H. Lee et al., «Quick-Delivery Mould Fabricated via Stereolithography to Enhance Manufacturing Efficiency», Micromachines, vol. 15, fasc. 11, p.1345, ott. 2024.

DOI: 10.3390/mi15111345

Google Scholar

[8] T. Hanemann, A. Klein, H. Walter, D. Wilhelm, e S. Antusch, «Evaluation of Material Extrusion Printed PEEK Mould Inserts for Usage in Ceramic Injection Moulding», J. Manuf. Mater. Process., vol. 8, fasc. 4, p.156, lug. 2024.

DOI: 10.3390/jmmp8040156

Google Scholar

[9] Y. Lay, R. Roj, M. Bonnet, R. Theiß, e P. Dültgen, «Design and Validation of Additively Manufactured Injection Moulds», 3D Print. Addit. Manuf., vol. 10, fasc. 2, p.226–235, apr. 2023.

DOI: 10.1089/3dp.2021.0132

Google Scholar

[10] H. M. Silva, «A review of the design optimization of conformal cooling channels in injection moulds», Int. J. Adv. Manuf. Technol., vol. 138, fasc. 7, p.2653–2671, giu. 2025.

DOI: 10.1007/s00170-025-15234-2

Google Scholar

[11] D. Chalicheemalapalli Jayasankar, T. Tröster, e T. Marten, «Optimizing Injection Moulding Tool Design with Additive Manufacturing: A Focus on Thermal Performance and Process Efficiency», Materials, vol. 18, fasc. 3, p.571, gen. 2025.

DOI: 10.3390/ma18030571

Google Scholar

[12] D. Yao, S.-C. Chen, e B. H. Kim, «Rapid thermal cycling of injection moulds: An overview on technical approaches and applications», Adv. Polym. Technol., vol. 27, fasc. 4, p.233–255, 2008.

DOI: 10.1002/adv.20136

Google Scholar

[13] S.-C. Chen, W.-R. Jong, Y.-J. Chang, J.-A. Chang, J.-C. Cin, «Rapid mould temperature variation for assisting the micro injection of high aspect ratio micro-feature parts using induction heating technology», J. Micromech. Microeng., vol. 16, fasc. 9, p.1783–1791, 2006.

DOI: 10.1088/0960-1317/16/9/005

Google Scholar

[14] Q. Su, N. Zhang, M. D. Gilchrist, «The use of variotherm systems for microinjection moulding», J. Appl. Polym. Sci., vol. 133, p.42962, 2016.

DOI: 10.1002/app.42962

Google Scholar

[15] F. De Santis, R. Pantani, «Development of a rapid surface temperature variation system and application to micro-injection moulding», J. Mater. Process. Technol., vol. 237, p.1–11, 2016.

DOI: 10.1016/j.jmatprotec.2016.05.023

Google Scholar

[16] J. Giboz, T. Copponnex, P. Mélé, «Microinjection moulding of thermoplastic polymers: a review», J. Micromech. Microeng., vol. 17, p. R96–R109, 2007.

DOI: 10.1088/0960-1317/17/6/R02

Google Scholar

[17] K. Oubellaouch, M. Sorgato, e B. Reggiani, «A Two-Step Simulation Approach to Predict Surface Micro-textures Replication in Injection-Moulded Polymeric Parts», in Selected Topics in Manufacturing: Emerging Trends from the Perspective of AITeM's Young Researchers, L. Fratini, L. M. Galantucci, e L. Settineri, A c. di, Cham: Springer Nature Switzerland, 2025, p.157–173.

DOI: 10.1007/978-3-031-99501-9_10

Google Scholar

[18] Giulia Zaniboni, Riccardo Pelaccia, Leonardo Orazi, Rossella Surace, Giovanna Rotella, Vito Basile, Resin moulds to improve thermal energy consumption in injection moulding process, Materials Research Proceedings, Vol. 57, pp.393-400, 2025.

DOI: 10.21741/9781644903735-46

Google Scholar

[19] Serratore, Giuseppe, et al. "Life cycle assessment-guided design for sustainable microinjection moulds." Materials Research Proceedings 54 (2025).

Google Scholar