Session: 04-09-01: Design of Engineering Materials

Paper Number: 167258

Composite Materials Injection Molds for Batch Production 

 

 Abstract

In today's manufacturing world, efficiency, cost-effectiveness and sustainability are more important than ever. Composite materials are emerging as a game change in mold manufacturing, offering a light and durable alternative to traditional metal injection molds. Although metal injection molds have been the industry pattern for decades, they have come with disadvantages: high production costs, significant weight and gradual wear that leads to inefficiencies over time. On the other hand, metal made injection molds are more appropriate and economically justified for mass production. Manufacturing strategies are shifting towards batch production, where more variety and less volume is needed. This research is driven by the need for better performance and more suitable injection molds that are not only more economical but also more sustainable. The goal is to optimize composite materials exploring various combinations of fiber matrix, manufacturing techniques, and reinforcement strategies to develop injection molds that can support repeated industrial use without compromising performance.

This research is about pushing the boundaries of materials science and engineering to meet the high demands of industries like aerospace, automotive, and consumer goods manufacturing for batch production. Shifting from metal to composite injection molds has the potential to improve production efficiency, and reduce costs. By systematically analyzing material properties and refining fabrication methods, this research seeks to make composite injection molds a practical, competitive alternative to traditional metal injection molds for batch production.

This research follows a structured, multi -phase approach. It begins with a comprehensive literature review to identify the most promising fiber matrix combinations, focusing on carbon fiber, fiberglass and hybrid composites. Selected materials are then manufactured to mold prototypes using advanced techniques such as vacuum -assisted resin transmission (VAGM) and additive manufacturing production. These prototypes undergo strict mechanical and thermal testing, including tensile, compression, influence and heat resistance assessments. Calculation modeling and statistical analysis are used to evaluate performance trends and limit material selection, ensuring that the most durable and effective composite formulations are identified.

Recent tests show that certain composite materials offer excellent thermal stability, mechanical strength, and resistance to wear, making them a strong alternative to traditional metal injection molds. Early results suggest that composite injection molds can perform just as well, if not better, than metal ones while being much lighter and more cost-effective for batch production. Future research will focus on improving their durability under repeated thermal cycling and mechanical stress to ensure long-term reliability in industrial environments.

The purpose of this research is to give industries a practical guide and data supported by the adoption of composite injection molds. By developing better materials that improve efficiency, cutting costs and promoting sustainable batch production, it intends to help manufacturers remain competitive and adopt smarter and more effective solutions.

Presenting Author: Yussef Syed Ahmed Western Carolina University

Presenting Author Biography: Yussef Sayed Ahmed is a mechanical engineer specializing in manufacturing, machine design, and product design. I worked as a mechanical designer at Royal Company for three years before starting my master's degree at Western Carolina University. I am passionate about engineering innovation and process improvement, always looking to enhance my skills through advanced coursework and hands-on projects.

Authors:

Basel Alsayyed Western Carolina University
Yussef Syed Ahmed Western Carolina University