Evaluation of polycarbonate additive manufacturing molds for autoclave molding

In Fiber Reinforced Plastics (FRP) molding, molds made of metal or epoxy resin blocks are commonly used, but the production time and material costs are high and not suitable for prototyping and small volume production. 3D printed molds have the potential to overcome these limitations, which would also enable frequent mold shape adjustment. The present study aimed to investigate the viability of the treated product as a mold for autoclave molding and establish a simple surface treatment method for additive manufacturing products produced by Fused Deposition Modeling. Polycarbonate resin was used to manufacture laminated male molds for the upper core and midsole of shoes, and the surface of the molds was treated with three different methods (clamping, treatment by aluminum tape and fluorine tape). The deformation of the molds due to autoclave molding was investigated by comparing the male molds before and after autoclave molding and computer-aided design data. In the clamping treatment, it was difficult to remove the mold after autoclave molding due to resin getting into the mold and fiber exposure due to resin loss was also observed. In the aluminum tape treatment, the midsole mold was deformed. On the other hand, the fluorine tape treatment enabled easy mold removal, and little deformation and weight change of the molds were observed. The results of this study suggest that the using laminated products made of polycarbonate resin can be used as molds for autoclave molding when combined with pre-treatment using fluorine tape.