Feature-Dependent Injection Moulds for Medical Products Optimized via the Capabilities of Metal 3D Printing

This paper examines the capabilities of injection moulding in the production of medical devices, with a particular focus on the potential of additive manufacturing in the construction of cooling channels. Conventionally, cooling channels in injection moulds have been limited to linear configurations. However, the size, integration and structure of the cooling channels have a massive impact on cooling efficiency, part quality, cycle time and overall process efficiency. This leads to the need for new structural manufacturing methods. The introduction of additive manufacturing offers freedom of design and the ability to create cooling channels that conform to the tool’s geometry. With the new advantages introduced by additive manufacturing come new difficulties and innovations in the development of conformal cooling channels. Examined through a case study of a medical component in this paper. Producing cooling channels that conform to the complex contours of the mould requires complex design processes. This paper investigates the challenges of designing these channels to ensure precision and efficiency in the development of conformal cooling channels. A key focus is the comparative analysis between optimised cooling channels, crafted through additive manufacturing, and their conventionally machined counterparts. Using simulation techniques, the study examines the reduced temperatures achieved by the conformal channels compared to their conventional counterparts. The implications of integrating additive manufacturing into the injection moulding tool for medical devices are also discussed. By incorporating additive manufacturing into the process of creating the cooling channels, increased efficiency and reduced temperature are achieved, as demonstrated by the simulation results. Within the scope of this study, emphasis is placed on investigating the potential impact on part quality, manufacturing speed, and overall process efficiency, beyond the immediate benefits observed in cooling channel design.