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The use of stereolithography (SL) as a rapid tooling technique for injection moulding provides a low cost and quick alternative to hard tooling methods when producing a small quantity of parts. However, previous work has shown that different characteristics are developed by crystalline plastic parts produced from SL moulds and those produced from conventional tooling methods. Differing characteristics means that the parts are not truly the same as those that would be produced by hard tooling and highlights a disadvantage to SL tooling. Such differences are due to the cooling rate experienced by the part. Parts produced from SL moulds are cooled more slowly than those from metal tools as a result of the differing thermal conductivity of the mould material itself. This work concerned establishing the extent of the difference in the heat transfer characteristics. The different cooling rates were demonstrated by real-time data acquisition. The results illustrated the very different thermal history imparted on the moulding that is likely to be the cause of characteristic differences in the parts. The work then describes how the thermal conditions experienced in SL moulds can be used to an advantage. A case study details the use of SL moulds for the injection moulding of polyether-ether-ketone, which has high process parameter demands. The results of the case study have shown that not only is the SL rapid tooling method capable of producing a low volume of polyether-ether-ketone parts, but also under conditions that would not be possible using a metal mould. The thermal characteristics of SL moulds allowed fully crystalline polyether-ether-ketone parts to be produced with the mould at room temperature; the equivalent steel mould would require a pre-moulding temperature of about 200°C and much higher injection pressures and speeds. [ABSTRACT FROM AUTHOR]

Multi-Photon Polymerization (MPP) is a technique used to fabricate complex micro-scale 3D structures using ultra-short laser pulses. Typically, MPP is used to manufacture micron-scale components in photopolymer materials. However, the development of micron scale processes that can produce components from multiple materials within a single manufacturing step would be advantageous. This would allow the inclusion of particles that are manipulated and embedded within structures with sub-micron feature sizes. To achieve this, an MPP system was combined with an optical trapping (OT) setup in order to independently manipulate microparticles in the x, y and z planes. Particles were transported into the fabrication site using the OT and encapsulated using the MPP laser. Here it is shown that combining the OT capabilities with an additive manufacturing technique enables the production of complex multi-material artifacts. [ABSTRACT FROM AUTHOR]

The direct use of moulds produced by stereolithography (SL) provides a rapid tooling technique which allows low volume production by plastic injection moulding. The greatest advantage of the process is that it provides parts that are the same as those that would be produced by metal tooling in a fraction of the time and cost. However, work by the authors demonstrates that the parts possess different characteristics to those produced by metal tooling. This knowledge defies the greatest advantages of the SL injection moulding tooling process – the moulded parts do not replicate parts that would be produced by metal tooling. This work specifically demonstrates that a different rate of part shrinkage is experienced and subsequently investigates the mechanisms in SL tooling that induce these different part properties. The work culminates in different approaches to modifying the moulding process which allow the production of parts whose key morphological characteristics are closer to those that have been produced from metal moulds. [ABSTRACT FROM AUTHOR]