Development of injection molding tooling with conformal cooling channels fabricated by optimal process parameters

Wax patterns can be used in precision casting. Developing a low-cost approach to rapid fabrication of customized wax patterns with complex geometry is an important research issue. In this study, a wax filament with low melting point is developed for fabricating wax patterns using additive manufacturing technology. The optimal process parameters for producing wax pattern were investigated using the Taguchi design method. The results show that the most important control factor affecting the form accuracy of the fabricated wax patterns is the flow of nozzle, followed by print speed. The form accuracy of the fabricated wax patterns has the lower impact for the nozzle temperature and bed temperature. The optimal process parameters for producing wax patterns are nozzle temperature of 64 °C, print speed of 60 mm/s, bed temperature of 40 °C, and flow of nozzle of 100%. An injection molding tooling is fabricated by wax conformal cooling channels fabricated by the optimal process parameters. © 2018, Springer-Verlag London Ltd., part of Springer Nature.