Applicability of Additively Manufactured Fiber-Reinforced Thermoplastic Composite Mold for Thermoplastic Composite Thermoforming Process

Thermoforming is a widely used manufacturing process that traditionally relies on metal molds to shape thermoplastic polymer sheets. However, the high costs and long lead times associated with metal mold fabrication present significant challenges. This research explores the use of additively manufactured carbon fiber-reinforced Polyphenylene Sulfide (PPS) composites as an innovative substitute for metal molds in the thermoforming process, specifically focusing on the molding of fiber-reinforced Polyamide 6 (PA6) and Polyetherketoneketone (PEKK) composite laminates. A key focus of this study is evaluating the performance of 3D-printed thermoplastic composite molds, assessing their thermal performance and durability when exposed to elevated temperatures during the thermoforming process. Experiments were conducted to measure temperature distribution across the mold using a thermal camera. In addition, digital image correlation (DIC) technology was employed to investigate mold deformation during and after the forming cycles. Digital Image Correlation (DIC) is a non – contact optical method for measuring surface displacement and strain. It tracks speckle pattern movement on a specimen to determine deformation during forming. To enhance mold protection, a thermal barrier made of an aluminum layer was installed between the 3D-printed mold and the formed composite laminate to dissipate heat during the forming process. The results reveal the impact of the thermal barrier on mold stability and deformation, demonstrating that composite molds offer a viable alternative to metal molds for thermoforming. This research highlights the potential for cost-effective, efficient, and sustainable mold solutions across multiple industries, while maintaining the necessary performance and technical standards.