Purpose: The purpose of this study is to compare the overall performance of the injection moulding process by using metallic inserts produced by both conventional technologies and selective laser melting (SLM). Design/methodology/approach: A systematic methodology is proposed for prior evaluation of the effectiveness of conformal cooling channels to reduce cycle time and/or to reduce the scrap rate. Findings: The mould was reengineered considering the SLM process and manufactured. Injection trials were carried out to validate expectations provided by injection simulations, which resulted on good quality parts and a significant decrease on cooling time, and, consequently, on the overall cycle time. The minimisation of scrap provided energy savings and time-to-market reduction. Research limitations/implications: The initial costs for AM tools still pose some doubts on decision-makers. The challenge of this study is to implement the methodology on a small-scale production and still ensure that benefits are achieved. Practical implications: The case study selected for this research work is based on a parking sensor housing, which is a plastic part assembled on the vehicle’s front and rear bumpers, therefore, with aesthetics concerns. The part produced with the conventional mould exhibits surface defects that, to be minimised (not eliminated), require a longer packing time to diminish the sink marks. Social implications: The economic impact of the use of SLM is relevant despite the low batch size for the case study presented. Energy savings are achieved due to scrap reduction and shorter cycle time. Originality/value: The systematic methodology proposed for prior evaluation of the advantages of conformal cooling is possible to be applied both on small scale and high production series.

Purpose: Laser milling is a recent process in mould making, providing several advantages over traditional mould making technologies by reducing manufacturing time, shortening the number of machining operations and avoiding expensive electrodes. This paper investigates the influence of the operating conditions on both the surface quality and material removal for two types of materials commonly used in mould making.Design/methodology/approach: Laser scanning strategies and operating parameters like scanning speed and laser frequency and power were tested, regarding surface quality and material removal rate. The most representative parameter of the real surface quality, R_k, the core roughness parameter, is used to characterise the surface finishing on all cavities.Findings: The findings of this research work suggest that it is possible to significantly reduce processing time by increasing the hatch spacing up to a value close to the laser beam spot diameter, without compromising surface quality. Lower pulse frequencies and laser power are more appropriate whenever surface quality is an issue. Higher material removal rates are achieved by increasing both the pulse frequency till an optimum value and laser power. The increase of scanning speed reduces the material removal rate by decreasing the overlap degree between individual laser pulses.Originality/value: The originality is to correlate the influence of the operating conditions of laser milling on both the surface quality and material removal for different types of materials.

Achieving good quality of products from plastic injection moulding processes is very challenging, since the process comprises many affecting parameters. Common defects such as warpage are hard to avoid, and the defective parts will eventually go to waste, leading to unnecessary costs to the manufacturer. The use of recycled material from postindustrial waste has been studied by a few researchers. However, the application of an optimisation method by which to optimise processing parameters to mould parts using recycled materials remains lacking. In this study, Response Surface Methodology (RSM) and Particle Swarm Optimisation (PSO) methods were conducted on thick plate parts moulded using virgin and recycled low-density polyethylene (LDPE) materials (100:0, 70:30, 60:40 and 50:50; virgin to recycle material ratios) to find the optimal input parameters for each of the material ratios. Shrinkage in the x and y directions increased in correlation with the recycled ratio, compared to virgin material. Meanwhile, the tensile strength of the thick plate part continued to decrease when the recycled ratio increased. R30 (70:30) had the optimum shrinkage in the x direction with respect to R0 (100:0) material where the shrinkage increased by 24.49% (RSM) and 33.20% (PSO). On the other hand, the shrinkage in the y direction for R30 material increased by 4.48% (RSM) and decreased by 2.67% (PSO), while the tensile strength of R30 (70:30) material decreased by 0.51% (RSM) and 2.68% (PSO) as compared to R0 (100:0) material. Validation tests indicated that the optimal setting of processing parameter suggested by PSO and RSM for R0 (100:0), R30 (70:30), R40 (60:40) and R50 (50:50) was less than 10%.

Digital twin technology offers immersive and cost-effective solutions for workforce training, yet its practical implementation within SME training frameworks remains limited. This study develops and evaluates the Digital Twin Framework for Workforce Training (DT4WFT), addressing key challenges such as resource constraints and precision through tools like Siemens NX Mechatronic Concept Design (MCD) and StoneCUT@Line^®. Employing a mixed-methods approach, qualitative insights from managers, and quantitative analysis demonstrated the framework’s potential to enhance operator performance, improve efficiency, and reduce lead times. However, the validation was based solely on managerial perceptions, as the framework has not yet been implemented in real-world settings. Statistical analysis confirmed strong correlations between the framework’s perceived implementation and improved training outcomes, highlighting its scalability and adaptability. Future research should focus on practical implementation, cross-industry applications, and longitudinal studies to evaluate sustained impacts, ensuring the DT4WFT framework’s broader relevance and effectiveness in workforce development.