Transforming plastic injection molding with additive manufacturing: a novel systematic review of innovative approaches to insert production

Purpose This paper studies the feasibility of additive manufacturing (AM) processes and their potential materials to produce mold inserts for injection molding (IM) of plastic parts. This study aims to describe the technological advancements and practical implications of integrating AM with IM to produce plastic parts, reducing the gap and determining the feasibility of AM for insert production. Design/methodology/approach A literature search of different databases was done. Applying the PRISMA methodology, the 67 most relevant articles between 2013 and 2024 were selected. From these, a bibliometric analysis was performed, and the main results regarding the mechanical properties and the number of injection cycles achieved by inserts were extracted. Findings Material jetting (MJT), vat photopolymerization via ultraviolet light laser (VPP-UVL) and laser powder bed fusion using metal powders (PBF-LB/M) are the most useful AM processes reported in the literature to produce inserts for IM. Studies show that the maximum number of successful injection cycles achieved with these AM inserts has been 116, 85 and more than 500 cycles, respectively. The molded geometry, the injected material and the IM parameters influence the number of injection cycles, being the injection pressure, the mold temperature and the injection temperature the most critical parameters to consider in extending the life of the inserts. Originality/value To the best of the authors’ knowledge, this study provides the first systematic review with a comprehensive overview of this innovative approach to evaluate the emerging directions, current barriers and future potential of using AM with IM to manufacture plastic parts. As such, this study highlights the primary findings in the literature concerning AM processes and the materials commonly used to manufacture inserts for IM.