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DIEHISTORYMEORICEWILKESABSTRACTFUNCTIONALPARTSARENEEDEDFORDESIGNVERICATIONTESTING,ELDTRIALS,CUSTOMEREVALUATION,ANDPRODUCTIONPLANNINGBYELIMINATINGMULTIPLESTEPS,THECREATIONOFTHEINJECTIONMOLDDIRECTLYBYARAPIDPROTOTYPINGRPPROCESSHOLDSTHEBESTPROMISEOFREDUCINGTHETIMEANDCOSTNEEDEDTOMOLDLOWVOLUMEQUANTITIESOFPARTSTHEPOTENTIALOFTHISINTEGRATIONOFINJECTIONMOLDINGWITHRPHASBEENDEMONSTRATEDMANYTIMESWHATISMISSINGISTHEFUNDAMENTALUNDERSTANDINGOFHOWTHEMODICATIONSTOTHEMOLDMATERIALANDRPMANUFACTURINGPROCESSIMPACTBOTHTHEMOLDDESIGNANDTHEINJECTIONMOLDINGPROCESSINADDITION,NUMERICALSIMULATIONTECHNIQUESHAVENOWBECOMEHELPFULTOOLSOFMOLDDESIGNERSANDPROCESSENGINEERSFORTRADITIONALINJECTIONMOLDINGBUTALLCURRENTSIMULATIONPACKAGESFORCONVENTIONALINJECTIONMOLDINGARENOLONGERAPPLICABLETOTHISNEWTYPEOFINJECTIONMOLDS,MAINLYBECAUSETHEPROPERTYOFTHEMOLDMATERIALCHANGESGREATLYINTHISPAPER,ANINTEGRATEDAPPROACHTOACCOMPLISHANUMERICALSIMULATIONOFINJECTIONMOLDINGINTORAPIDPROTOTYPEDMOLDSISESTABLISHEDANDACORRESPONDINGSIMULATIONSYSTEMISDEVELOPEDCOMPARISONSWITHEXPERIMENTALRESULTSAREEMPLOYEDFORVERICATION,WHICHSHOWTHATTHEPRESENTSCHEMEISWELLSUITEDTOHANDLERPFABRICATEDSTEREOLITHOGRAPHYSLMOLDSKEYWORDSINJECTIONMOLDINGNUMERICALSIMULATIONRAPIDPROTOTYPINGINTRODUCTIONININJECTIONMOLDING,THEPOLYMERMELTATHIGHTEMPERATUREISINJECTEDINTOTHEMOLDUNDERHIGHPRESSURE1THUS,THEMOLDMATERIALNEEDSTOHAVETHERMALANDMECHANICALPROPERTIESCAPABLEOFWITHSTANDINGTHETEMPERATURESANDPRESSURESOFTHEMOLDINGCYCLETHEFOCUSOFMANYSTUDIESHASBEENTOCREATETHEINJECTIONMOLDDIRECTLYBYARAPIDPROTOTYPINGRPPROCESSBYELIMINATINGMULTIPLESTEPS,THISMETHODOFTOOLINGHOLDSTHEBESTPROMISEOFREDUCINGTHETIMEANDCOSTNEEDEDTOCREATELOWVOLUMEQUANTITIESOFPARTSINAPRODUCTIONMATERIALTHEPOTENTIALOFINTEGRATINGINJECTIONMOLDINGWITHRPTECHNOLOGIESHASBEENDEMONSTRATEDMANYTIMESTHEPROPERTIESOFRPMOLDSAREVERYDIFFERENTFROMTHOSEOFTRADITIONALMETALMOLDSTHEKEYDIFFERENCESARETHEPROPERTIESOFTHERMALCONDUCTIVITYANDELASTICMODULUSRIGIDITYFOREXAMPLE,THEPOLYMERSUSEDINRPFABRICATEDSTEREOLITHOGRAPHYSLMOLDSHAVEATHERMALCONDUCTIVITYTHATISLESSTHANONETHOUSANDTHTHATOFANALUMINUMTOOLINUSINGRPTECHNOLOGIESTOCREATEMOLDS,THEENTIREMOLDDESIGNANDINJECTIONMOLDINGPROCESSPARAMETERSNEEDTOBEMODIEDANDOPTIMIZEDFROMTRADITIONALMETHODOLOGIESDUETOTHECOMPLETELYDIFFERENTTOOLMATERIALHOWEVER,THEREISSTILLNOTAFUNDAMENTALUNDERSTANDINGOFHOWTHEMODICATIONSTOTHEMOLDTOOLINGMETHODANDMATERIALIMPACTBOTHTHEMOLDDESIGNANDTHEINJECTIONMOLDINGPROCESSPARAMETERSONECANNOTOBTAINREASONABLERESULTSBYSIMPLYCHANGINGAFEWMATERIALPROPERTIESINCURRENTMODELSALSO,USINGTRADITIONALAPPROACHESWHENMAKINGACTUALPARTSMAYBEGENERATINGSUBOPTIMALRESULTSSOTHEREISADIRENEEDTOSTUDYTHEINTERACTIONBETWEENTHERAPIDTOOLINGRTPROCESSANDMATERIALANDINJECTIONMOLDING,SOASTOESTABLISHTHEMOLDDESIGNCRITERIAANDTECHNIQUESFORANRTORIENTEDINJECTIONMOLDINGPROCESSINADDITION,COMPUTERSIMULATIONISANEFFECTIVEAPPROACHFORPREDICTINGTHEQUALITYOFMOLDEDPARTSCOMMERCIALLYAVAILABLESIMULATIONPACKAGESOFTHETRADITIONALINJECTIONMOLDINGPROCESSHAVENOWBECOMEROUTINETOOLSOFTHEMOLDDESIGNERANDPROCESSENGINEER2UNFORTUNATELY,CURRENTSIMULATIONPROGRAMSFORCONVENTIONALINJECTIONMOLDINGARENOLONGERAPPLICABLETORPMOLDS,BECAUSEOFTHEDRAMATICALLYDISSIMILARTOOLMATERIALFORINSTANCE,INUSINGTHEEXISTINGSIMULATIONSOFTWAREWITHALUMINUMANDSLMOLDSANDCOMPARINGWITHEXPERIMENTALRESULTS,THOUGHTHESIMULATIONVALUESOFPARTDISTORTIONAREREASONABLEFORTHEALUMINUMMOLD,RESULTSAREUNACCEPTABLE,WITHTHEERROREXCEEDING50THEDISTORTIONDURINGINJECTIONMOLDINGISDUETOSHRINKAGEANDWARPAGEOFTHEPLASTICPART,ASWELLASTHEMOLDFORORDINARILYMOLDS,THEMAINFACTORISTHESHRINKAGEANDWARPAGEOFTHEPLASTICPART,WHICHISMODELEDACCURATELYINCURRENTSIMULATIONSBUTFORRPMOLDS,THEDISTORTIONOFTHEMOLDHASPOTENTIALLYMOREINUENCE,WHICHHAVEBEENNEGLECTEDINCURRENTMODELSFORINSTANCE,3USEDASIMPLETHREESTEPSIMULATIONPROCESSTOCONSIDERTHEMOLDDISTORTION,WHICHHADTOOMUCHDEVIATIONINTHISPAPER,BASEDONTHEABOVEANALYSIS,ANEWSIMULATIONSYSTEMFORRPMOLDSISDEVELOPEDTHEPROPOSEDSYSTEMFOCUSESONPREDICTINGPARTDISTORTION,WHICHISDOMINATINGDEFECTINRPMOLDEDPARTSTHEDEVELOPEDSIMULATIONCANBEAPPLIEDASANEVALUATIONTOOLFORRPMOLDDESIGNANDPROCESSOPTIMIZATIONOURSIMULATIONSYSTEMISVERIEDBYANEXPERIMENTALEXAMPLEALTHOUGHMANYMATERIALSAREAVAILABLEFORUSEINRPTECHNOLOGIES,WECONCENTRATEONUSINGSTEREOLITHOGRAPHYSL,THEORIGINALRPTECHNOLOGY,TOCREATEPOLYMERMOLDSTHESLPROCESSUSESPHOTOPOLYMERANDLASERENERGYTOBUILDAPARTLAYERBYLAYERUSINGSLTAKESADVANTAGEOFBOTHTHECOMMERCIALDOMINANCEOFSLINTHERPINDUSTRYANDTHESUBSEQUENTEXPERTISEBASETHATHASBEENDEVELOPEDFORCREATINGACCURATE,HIGHQUALITYPARTSUNTILRECENTLY,SLWASPRIMARILYUSEDTOCREATEPHYSICALMODELSFORVISUALINSPECTIONANDFORMTSTUDIESWITHVERYLIMITEDFUNCTIONALAPPLICATIONSHOWEVER,THENEWERGENERATIONSTEREOLITHOGRAPHICPHOTOPOLYMERSHAVEIMPROVEDDIMENSIONAL,MECHANICALANDTHERMALPROPERTIESMAKINGITPOSSIBLETOUSETHEMFORACTUALFUNCTIONALMOLDS1DIEPOSITIONININDUSTRIALPRODUCTIONMOLDISAHIGHVOLUMEPRODUCTSWITHTHESHAPETOOL,ISTHEMAINPROCESSOFINDUSTRIALPRODUCTIONEQUIPMENTWITHMOLDCOMPONENTS,WITHHIGHEFFICIENCY,GOODQUALITY,LOWCOST,SAVINGENERGYANDRAWMATERIALSANDASERIESOFADVANTAGES,WITHTHEMOLDWORKPIECESPOSSESSHIGHACCURACY,HIGHCOMPLEXITY,HIGHCONSISTENC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