Realization of an ultrasound compression mold in 3D printing
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Table of Contents
LGP2 is a laboratory of process engineering for biorefinery, bio-based materials and functional printing, situated in Grenoble, France. The objective was to explore a new way in producing materials from cellulose-derived biomass using the Ultrasound Compression process to serve various industries such as real estate and packaging.
Today, biomass-derived materials are mainly produced through thermocompression: the mould is heated, which also heats the material inside.
The need
The research centre needed a mould made of high-precision plastic material that could withstand high temperatures as they reach 200 °C. The metal mould could not be used because of the contact between the ‘sonotrode’, which vibrates at ultrasonic frequencies. The mould also had to have an ISO H8F7 precision slot and perfectly smooth internal surfaces.
"Ultrasound Compression does not allow the use of metal molds. The choice of precision stereophotography is forced because of the need for smooth surfaces with respect to dimensional compliance and 90° angles in addition to thermal resistance."
DWS Systems produced the mould with Therma DM570 material and the printer DW 029MKIII.
The mold was tested at the LGP2 laboratory, using the sonotrode. In addition to maintaining dimensional compliance of fundamental importance, given the precision required, it resisted the high temperature emitted and the result was more than satisfactory: the material was produced in bio mass perfectly.
The benefit of 3D printing
Smooth surfaces
Internal corners at 90°
Temperature resistance
Meets ISO H8F7 accuracy
Biomass material can be produced by ultrasonic compression
Resistant to ultrasound
Therma DM570
Material for ultra-detailed mold manufacturing using 3D printing
