Mould temperature control has a significant influence on component quality and costs in the plastic injection moulding process. In the case of standard applications isothermal temperature control, in which the mould temperature is maintained at one level, is sufficient. For special applications (e.g. plastic optics; long, thin components; moulding of microstructures) variothermal temperature control using cyclically changing temperatures is beneficial. Therefore, the use of infrared radiators offers advantages in terms of achievable temperatures and investment costs but at low heating rates and efficiency. This paper therefore investigates the possibility of increasing the efficiency of energy input by infrared radiation into metals in particular into aluminium. For this purpose, a simulation model is developed. The numeric models used are validated by means of experiments. A short-wave infrared radiator is investigated, consisting of a tungsten filament in a quartz glass tube. The emitter power is varied from 1200 to 400 W. An aluminium sample with a thickness of 10 mm and a square base with an edge length of 60 mm is investigated. The temperature is measured on the non-irradiated side in the centre of the sample surface and at a distance of 20 mm from it while being irradiated. For the numerical model, a ray tracing simulation is carried out in a first step, the result of which is used as a Neumann boundary condition for a thermal simulation in second step. The model created can serve as a basis for the thermal design of more complex geometries.

Multi-material structures made from renewable materials are increasingly being addressed in research and industry. Especially lightweight applications based on wood and polymer materials offer an important opportunity to reduce weight and CO₂ emissions, and thus create a sustainable economy. When establishing new material combinations, it is necessary to take economical and efficient manufacturing processes into count to enable the market entry. Therefore, the existing manufacturing processes needed to be adapted and improved in terms of the specific machining characteristic of the wood material. This study targets a combined process where a forming and shear-cutting process is also integrated in an injection-molding tool. The findings on the shear-cutting process of wood veneers are not widely investigated yet. Therefore, process and material-related dependences like cutting velocity, tool shape design, and preconditioning of wood veneers were examined. The target values cutting force and cutting-edge quality were used to describe the relations. The results showed specific damage and fiber fractions of the wood material compared to the isotropic materials (e.g., metal). In addition, low cutting forces appeared by realizing a drawing cut and high cutting speeds. A decrease in the cutting force with a higher moisture content could not be shown for the used wood types.

Selective laser sintering (SLS) is currently in transition to the production of functional components. However, the ability to apply it is confronted with new requirements for reliability and reproducibility. Therefore, an in-depth understanding of aging processes in polymers is essential. Regarding material traceability as well as defective component identification with subsequent cause tracing, the application of a material-inherent marking technology represents a solution. SLS in combination with modified polymers as a marking technology proves to be an efficient opportunity to produce reproducible and high-quality components due to an increased understanding of the process. Based on a selection of modified polymers for use in SLS, which were characterized in part I of the study, this work focuses on the experimental validation of the result. The influence of modified polymers on materials and component properties and the SLS process’s influence on the traceability of modified polymers are examined. Intrinsic and extrinsic material properties as well as mechanical properties, surface quality and sinter density are analyzed. No discernible influences of the modified polymers on the investigated properties could be observed and the traceability of the modified polymers could also be confirmed in the aged powder and component using mass spectroscopy.

Screw extrusion additive manufacturing (SEAM) is an additive manufacturing process in which plastic granulate is melted and extruded using a screw extruder. In contrast to filament-based processes, this enables higher output rates and a greater variety of materials. One of the main challenges is the efficient cooling of the extrudates. An optimized cooling system is presented and its application potential demonstrated.

Thermoforming enables the efficient processing of continuous fibre reinforced thermoplastic (CFRT) such as organo sheets into geometrically complex and structurally advantageous structures; however, resulting components are often hybrized through additional processes for an increased rigidity. For this, injection moulding is a widespread option, as it allows for the precise integration of plastic ribs into the thermoformed products, leading to improved structural integrity and mechanical stiffness [1, 2]. As thermoforming and injection moulding offer synergistic advantages, especially based on many related process steps, the processes can be successfully integrated [3]. When further manufacturing steps such as cutting are combined within this integrated process, the previously required handling steps are avoided entirely and the overall process cycle time can be reduced [4].Within the present research, the integration of multiple process steps into an integrative process chain is examined through a prototypical experimental setup. The investigated one-shot injection moulding mould (IMM) combines the thermoforming and trimming of the final contour as well as the injection moulding step within an index plate mould. This enables comparably short process cycles while maintaining part quality, such as the defined position of CFRT in edge contours. The process chain is validated and resulting demonstrator components are analyzed regarding the adhesion between CFRT and applied thermoplastics by applying tensile loads. Even in comparison to conventionally established processes, the investigated integrated process chain enables feasible results. Within the examined process parameters, the temperatures within the different system components significantly influence the overall part quality. Overall, the concept for an integrated process chain shows promise for further investigations, as it offers significant gains in overall process efficiencies through reduced handling steps and potential time savings.