A new hybrid process combining rapid tooling and machining to manufacture an injection mold with micro features

Injection molding is cost-effective to manufacture molded products by injection molding machine. A precision part with micro features can be fabricated effectively through the-state-of-art mold. The injection mold with micro features can be manufactured by the metal additive manufacturing technology. However, the surface quality of the injection mold is not acceptable. To cope with these challenges simultaneously, a novel concept was proposed. This work reports a new approach for rapid manufacturing precision injection molds with micro features by integrating additive manufacturing, rapid tooling, and micro-milling. It was found that of the dimensional accuracy of a precision component in the length, width, and height can be controlled at approximately 30 μm. Injection molding was performed using an injection mold with a micro feature of 950 μm and the dimensional accuracy of a precision wax pattern in the length, width, and micro features can be controlled at approximately 60 μm, 50 μm, and 10 μm, respectively. This work builds the foundation needed for hybrid manufacturing to be applicable toward fabrication of precision wax patterns with micro features efficiently and economically for trial production in the investment industry since the quality of wax patterns meets the standards of the general industry completely.