Abstract Functional parts are needed for design verification testing, field trials, customer eva luation, and production plan¬ning. By eliminating multiple steps, the creation of the injec¬tion mold directly by a rapid prototyping (RP) process holds the best promise of reducing the time and cost needed to mold low-volume quantities of parts. The potential of this integra¬tion of injection molding with RP has been demonstrated many times. What is missing is the fundamental understanding of how the modifications to the mold material and RP manufacturing process impact both the mold design and the injection mold¬ing process. In addition, numerical simulation techniques have now become helpful tools of mold designers and process engi¬neers for traditional injection molding. But all current simulation packages for conventional injection molding are no longer ap¬plicable to this new type of injection molds, mainly because the property of the mold material changes greatly. In this paper, an integrated approach to accomplish a numerical simulation of in¬jection molding into rapid-prototyped molds is established and a corresponding simulation system is developed. Comparisons with experimental results are employed for verification, which show that the present scheme is well suited to handle RP fabri¬cated stereolithography (SL) molds.
Keywords Injection molding Numerical simulation Rapid prototyping



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