Simulation and experimental assessment of a polymer‐based hybrid mould

Abstract Hybrid moulds incorporating polymeric materials in the moulding inserts have gained increasing attention in the injection moulding industry due to their potential to reduce product development time and lower tooling costs for short production runs. In this study, a hybrid mould prototype was applied to the production of a motorcycle display back housing, where mould inserts produced by additive manufacturing were integrated into a conventional mould structure. The inserts were fabricated using a photosensitive composite resin comprising a polymer matrix reinforced with ceramic particles. The performance of the hybrid mould was evaluated through plastic injection moulding simulation and static structural simulations. The polymeric‐based mould inserts were analysed for dimensional stability through warpage scanning and were experimentally tested by injection moulding trials of a glass‐fibre‐reinforced polybutylene terephthalate. A total of five back housings were produced before the structural integrity of the insert was compromised. These findings highlight the feasibility and durability limits of polymer‐based hybrid mould inserts under demanding processing conditions indicating that highly challenging processing materials, such as high‐fibre‐reinforced polymers, may limit the practical lifespan and effectiveness of polymer‐based hybrid moulds. © 2026 Society of Chemical Industry.