The generation of plastic parts in small volume batches has an enormous economic significance. Application fields for parts in small lot sizes are the fabrication of prototypes in the design process or individualized products. The goal thereby often is not only to produce show objects, but functional parts with specific materials, high dimensional accuracy and proper mechanical properties in a short amount of time. The conventional way to produce thermoplastic plastic parts is given by injection molding and extrusion. Characteristics for this technology are the resulting good and homogeneous mechanical component properties, but shape freedom is limited and the process is time consumptive because an individual tool is needed for each product. Depending on the design of the part the geometry of the tool can be complex and an iterative process is necessary to create a suitable mold. On the other hand, the technology of additive manufacturing is a growing market for the quick and cheap production of parts as prototypes, but still the range of materials is limited and anisotropic mechanical component properties are ongoing problems. The combination of both technologies is known as rapid tooling, where the mold is produced in an additive manufacturing process and then used in an injection molding or casting process. This approach combines the benefits of both technologies in term of time and cost efficiency and good component properties. Problems here are the combination of different materials for mold and component and the missing process knowledge and automatization. In this paper an extrusion-based additive manufacturing technology is used to combine additive manufacturing and injection infill generation for thermoplast in one process. The proposed working principle is to generate the outer contour of the part by filament extrusion as mold to ensure high accuracy and good surface quality and fill the mold using an extrusion process of polymer melt without filament generation. Accordingly, the mold becomes part of the component and the same material can be used for the mold and the infill. Since the viscosity of most thermoplastic polymer melts is too high to fill big structures and undercuts, an algorithm is proposed to generate a chamber structure inside the part. Consequently, the fabrication process consists of several iterative cycles of mold generation and injection processes. For this paper polyamide 6 is used to demonstrate the process. Experiments were performed to find the optimal chamber geometry and size to avoid holes and generate a high quality infill. Several component properties such as density, tensile strength and fabrication time are analyzed. In spite of still existing blowholes, a higher component density could be achieved with the proposed process compared to additive manufacturing. However, the tensile strength is still significantly lower. The failures appeared at the weld lines, where warm polymer melt was injected to already colder chambers below. Still manual processes are sources of possible defects as well. The integration of a RFID chip is shown as an additional feature of the process of easy integration of passive electronic elements.

The claim in additive manufacturing (AM) changes from simply producing prototypes as show objects to the fabrication of final parts and products in small volume batches. Thereby the focus is on freedom of material, dimensional accuracy and mechanical component properties. A novel extrusion-based AM technology has been developed focusing on these issues. The working principle is to form spheres from a thermoplastic polymer melt and build parts by single droplets. The material preprocessing is similar to the injection molding technology and enables a wide range of different thermoplastic polymers as build materials. With the droplet-based working principle high mechanical component properties and dimensional accuracy can be reached compared to similar processes. Further improvements to the process need a detailed knowledge of the physical effects during the build process. The temperature distribution during the manufacturing process determines at which temperature material is fused and how solidification takes place and shrinkage can occur or is suppressed. Thus, it has a significant influence on the mechanical properties and warpage effects of produced parts. In this work a thermal model is presented that describes the heat transfer during the build process. The necessary input data are the material properties and a print job description including the part geometry and building strategy. The basic idea is to simulate each single droplet deposition by applying a dynamic Finite Element Method. All relevant heat transfer effects are analyzed and represented in the model. The model was validated with measurements using a thermal imaging camera. Several measurements were performed during the build process and compared to the simulation results. A high accuracy could be reached with an average model error of about 4° Celsius and a maximal error of 10° Celsius.