Selective laser melting for improving quality characteristics of a prism shaped topology injection mould tool insert for the automotive industry

Manufacturing process constraints and design complexities are the main challenges that face aftermarket automotive industry. For reason, recently, selective laser melting (SLM) is being recognised as a viable approach in fabrication of injection moulding tool inserts. Due to its versatility, SLM technology capable producing freeform designs. first reported time, this study recognized for novel application overcoming prism shaped topology vehicle headlamp’s reflector insert. Henceforth, performance measures SLM-fabricated mould insert assessed comparison CNC-milled counterpart improve quality characteristics. Tests executed detailed paper divided into two stages; stage assesses both fabricated inserts terms manufacturability; second functionality end-products by measuring surface roughness, dimensional accuracy light reflectivity from reflectors. The results obtained show employing can offer an effective efficient alternative subtractive manufacturing, successfully with complex topology. Significant benefits product were achieved through use technology. it was concluded products proved have relatively lower values roughness their CNC counterparts.