Validation of Filament Materials for Injection Moulding 3D-Printed Inserts Using Temperature and Cavity Pressure Simulations

Using additive manufacturing for the design of inserts in injection moulding (IM) offers advantages in product development and customization. However, challenges related to operating temperature and mechanical resistance remain. This article presents a systematic screening methodology to evaluate the suitability of materials for specific applications. Ten commercial Material Extrusion (MEX) filaments were selected to produce test samples. Moldex3D simulation software was employed to model the IM process using two thermoplastics and to determine the temperature and pressure conditions that the printed inserts must withstand. Simulation results were critically interpreted and cross-referenced with the experimental material characterisations to evaluate material suitability. Nine of the ten MEX materials were suitable for IM with LDPE, and five with PP. Dimensional assessments revealed that six insert solutions required further post-processing for assembly, while three did not. All of the selected materials successfully survived 10 injection cycles without encountering any significant issues. The simulation results were validated by comparing temperature data from a thermal imaging camera during IM, revealing only minor deviations. The study concludes that combining targeted material characterization with CAE simulation provides an effective and low-cost strategy for selecting MEX filaments for injection moulding inserts, supporting rapid tooling applications in niche production.