Rapid tooling: comparative analysis of mechanical properties and energy efficiency in micro-injection mouldings using polymer and metal moulds

Rapid tooling enables the fabrication of polymer mould inserts, reducing reliance on subtractive manufacturing and mould heating. This study compares rapid polymer and metal tooling in micro-injection moulding, focusing on mechanical properties and energy efficiency. A micro-tensile bar design was used polymer mould and an aluminium counterpart. Both moulds were tested on a μ-IM machine, monitoring energy consumption during cycles. The study showed: (i) Polymer tooling achieves tensile properties within 6.4% of metal, (ii) up to 17.6% energy savings per moulding, (iii) rapid tools can replace metal for micro-products, offering energy efficiency, reduced lead times for product iterations.