The interlocking of two materials, where one features a surface lattice structure and the other is an injection-molded polymer, enables the formation of a mechanical bond without the need for additional adhesives. Such a joining method is applied in industries where high strength and bond reliability are required. The use of lattice structures as mechanical anchors for polymers during injection molding represents an innovative solution for improved adhesion in the automotive, aerospace, and medical industries.
In this work, the preparation of the injection molding technology for the production of interlocked specimens was presented, focusing on the study of the mechanical bond between 3D-printed lattice structures, fabricated using vat photopolymerization, and polymer. A mold insert compatible with the existing two-part moulding tool was designed and manufactured. A numerical simulation of the molding process of the cavity with the lattice structure was carried out using the Moldflow Advisor simulation software. The simulation results served as a basis for setting the injection molding process parameters on the Babyplast 6/10P machine. The appropriate molding parameters were determined experimentally. The quality of cavity filling around the lattice structures was evaluated visually. The inserts with surface lattice geometries were produced using 3D printing based on the vat photopolymerization principle. The lattice structures were of the BCCZ type with different strut diameters. The strength of the mechanical bonds was evaluated through tensile testing. The final results confirmed that the selected combination of geometry and process parameters enabled reliable cavity filling and ensured the mechanical integrity of the bond.
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