WO2019002913A1

WO2019002913A1 - Method for producing improved mold inserts and molding method

Info

Publication number: WO2019002913A1
Application number: PCT/IB2017/053846
Authority: WO
Inventors: Rajkumar KARTHIKEYAN; Matthew BURATTO; Murugan ARUMUGAM; Poovana THEETHIRA KUSHALAPPA; Nitesh Kumar SHET; Venkatesha Narayanaswamy
Original assignee: Sabic Global Technologies B.V.
Priority date: 2017-06-27
Filing date: 2017-06-27
Publication date: 2019-01-03

Abstract

A method for making a mold insert is provided. The method includes selectively forming a first bead of a first polymeric material onto a first target road to form a plurality of first layers that fuse to form a first melt-contacting surface of the first polymeric material and a first press-facing surface of the first polymeric material opposite the first melt-contacting surface. The first polymeric material comprises a high heat polymeric material. The first press- facing surface comprises a recessed configuration.

Description

METHOD FOR PRODUCING IMPROVED MOLD INSERTS AND MOLDING METHOD

BACKGROUND

[0001] Across different industry segments, original equipment manufacturers (OEMs) invest significant resources into conventional soft tooling (e.g., mold inserts) to produce pre- production parts for testing and validation during new product development. Conventional soft tooling development involves extensive resources and numerous tasks before completion of the tool. The cost and time consumption incurred to make the prototype tools can be considerable, while the life and the volume of parts produced from the prototype tool can be quite short. Current fused deposition molding (FDM) or PolyJet additive manufacturing (i.e., three- dimensional printing or 3D printing) processes use large amounts of material to produce 3D printed polymer inserts for injection molding.

[0002] Thus, it would be desirable to provide mold inserts that avoid the aforementioned disadvantages.

BRIEF DESCRIPTION

[0003] A method for making a mold insert includes selectively forming a first bead of a first polymeric material onto a first target road to form a plurality of first layers that fuse to form a first melt-contacting surface of the first polymeric material and a first press-facing surface of the first polymeric material opposite the first melt-contacting surface. The first polymeric material comprises a high heat polymeric material. The first press-facing surface comprises a recessed configuration.

[0004] In another aspect, a mold insert made by the above-described method is provided.

[0005] In yet another aspect, a method for producing an article includes aligning the above-described mold insert with a cavity insert or a core insert to form a gap therebetween, injecting a flowable polymeric material into the gap, and solidifying the flowable polymeric material to form the article.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The following figures are exemplary embodiments wherein the like elements are numbered alike.

[0007] FIGs. 1A-B are illustrations of an embodiment of a core insert.

[0008] FIGs. 2A-C are illustrations of another embodiment of a core insert. [0009] FIGs. 3A-B are illustrations of an embodiment of a cavity insert.

[0010] FIGs. 4A-B are illustrations of another embodiment of a core insert.

[0011] FIGs. 5A-C are illustrations of another embodiment of a core insert and an article produced from the core insert.

[0012] FIG. 6 is an illustration of another embodiment of a core insert.

[0013] FIGs. 7A-B are illustrations of another embodiment of a core insert.

[0014] FIG. 8 is an illustration of a method for producing a core insert and a cavity insert.

[0015] FIG. 9 is an illustration of another embodiment of a method for producing a core insert and a cavity insert.

[0016] FIG. 10 is an illustration of another embodiment of a method for producing a core insert and a cavity insert.

[0017] FIG. 11 is an illustration of an embodiment of a method for producing an article.

DETAILED DESCRIPTION

[0018] High heat polymeric materials like ULTEM™ polyetherimide can be used in additive manufacturing to form solid mold inserts to withstand the heat and pressure associated with injection molding. During the molding operation, heat can be conducted or absorbed from the injection molded part by the mold inserts. It was believed that, in order to have sufficient structural integrity to withstand molding pressures of 0.5 to 20 meganewtons (MN) for at least in the range of 500 to 5000 molding cycles, a thermoplastic mold must be solid. As a result, a large amount of the high heat polymeric material is used in the mold inserts. It has been unexpectedly discovered that a structural integrity to withstand molding pressures of 1.5 to 2 MN for at least 3,000 molding cycles, can be attained using a thermoplastic material (such as a polyetherimide), with a recessed configuration. In the recessed area can be reinforcement (e.g., additional material(s) and/or features such as at least one of ribs, honeycomb structures, and bosses). By using the reinforcement to support the high heat polymeric materials, the methods and mold inserts provided by the present disclosure avoid using large amounts of high heat polymeric materials while maintaining the physical properties needed for the molding processes used (e.g., compression strength, impact strength, or thermal resistance to maintain the shape and resist deformation or flow of the polymeric material of the mold insert).

[0019] As used herein, "high heat polymeric materials" refer to polymeric materials with a glass transition temperature greater than or equal to 200°C, or a melting point temperature greater than or equal to 200°C, or materials capable of withstanding temperatures greater than 200°C without deforming, cracking, or any other physical change that results in a mold insert comprising the high heat polymeric materials molding an article out of specification or being unable to mold an article. As used herein, "glass transition temperature" or (T_g) refers to a temperature at which an amorphous polymeric material changes from a hard, solid-like state into a viscous or elastic fluid-like state, as determined according to ASTM El 640- 13. As used herein, "melting point temperature" refers to a temperature at which a semi-crystalline or crystalline polymeric material changes from a hard, solid-like state into a viscous or elastic fluid-like state.

[0020] By using the methods of the present disclosure, the volume of material used for additive manufacturing of a mold insert can be reduced, for instance, by the design of the mold insert. The amount of material underneath the melt-contacting surface of the mold inserts described in the present disclosure can be reduced as compared to solid mold inserts by providing sufficient strength to the mold insert, for instance, by using high heat polymeric materials for the first polymeric material comprising a melt-contacting surface or reinforcement. It was believed that 3D printing of reinforcement such as honeycomb and ribbing structures into 3D printed mold inserts created discontinuities that resulted in weak mold inserts that risk crack propagation under compressive loads during the molding process. The present inventors have unexpectedly designed mold inserts including a recessed configuration with reinforcement (e.g., additional material and/or mechanical features such as ribs, honeycomb structures, or bosses) in the recess (e.g., on a press-facing surface of the mold insert) by printing with wide (e.g., greater than 0.1 millimeters, or 0.1 to 1.0 millimeters) beads of polymeric material to form the reinforcement. Such a 3D printed mold insert can withstand high injection or compression pressures during the molding process.

[0021] To avoid long product development life cycles when exploring multiple design variants, the present disclosure describes methods that reduce the amount of time required for making mold inserts for use in producing product development prototypes. Shorter

manufacturing times can be achieved by including a recessed configuration and/or by using materials that can be extruded at faster rates than high heat polymeric materials.

[0022] The processing time for producing a mold insert (e.g., using fused deposition modeling of a mold insert) comprising a press-facing surface with a recessed configuration can be reduced by an amount equal to or greater than 10%, for example, equal to or greater than 20%, or equal to or greater than 30%, of the time for producing the same mold insert devoid of the recessed configuration.

[0023] As used herein, "devoid of a recessed configuration" refers to a solid

configuration that does not include a concave shape on a press-facing surface of the mold insert.

[0024] A method for making a mold insert can comprise forming a first bead of a first polymeric material onto a first target road to form a plurality of first layers that fuse to form a first melt-contacting surface of the first polymeric material and a first press-facing surface of the first polymeric material opposite the first melt-contacting surface. The first polymeric material can comprise a high heat polymeric material (e.g., polyimide). The first press-facing surface can comprise a recessed configuration.

[0025] The method can further comprise forming a second bead of a second polymeric material onto a second target road adjacent to the first press-facing surface to form a plurality of second layers that fuse. The second polymeric material adjacent to the first polymeric material can have a second press-facing surface comprising a second recessed configuration.

[0026] The forming of the first bead and the forming of the second bead can be by selectively extruding the first bead and selectively extruding the second bead, respectively.

[0027] As used herein, "selectively forming" or "selectively extruding" refers to the forming or extruding of a material onto a target road in a directed or patterned manner according to a virtual (i.e., computer) article design, in contrast to forming or extruding a material according to an article design physically dictated by forming equipment or extruding equipment in macroscopic or bulk proportions (e.g., slit extrusion die of a bulk extruded film article or laminated pattern).

[0028] As used herein, "bead" refers to a droplet or a line of material. A bead can form a plurality of layers of a mold insert or a portion of a layer of a mold insert. For example, a bead can be a continuous line of material forming all the layers of a mold insert. Alternatively, a bead can be made up of discontinuously formed droplets or lines of material forming a plurality of layers of the mold insert.

[0029] As used herein, "target road" refers to a predetermined or precise path, shape, or pattern in three-dimensional space according to a virtual article design.

[0030] Multi-material additive manufacturing can be used rather than using a single polymeric material to build mold inserts, which can comprise a core insert or a cavity insert. As used herein, "core insert" refers to a mold insert configured to have a convex melt-contacting surface that produces an impression on one side of an article molded by the mold inserts. As used herein, "cavity insert" refers to a mold insert configured to have a concave melt-contacting surface produces an impression on one side of an article molded by the mold inserts. A core insert can be used in conjunction with a complimentary cavity insert to mold articles. A cavity insert can be used in conjunction with a complimentary core insert to mold articles.

[0031] Additive manufacturing processes, or three dimensional (3-D) printing, are generally defined as processes that build an object from a series of layers with each layer formed on top of the previous layer. For example, 3-D printing refers to a variety of processes including Fused Deposition Modeling (FDM) or Fused Filament Fabrication (FFF), Selective Laser Sintering (SLS), Stereolithography (SLA), Digital Light Processing (DLP), and 3D inkjet printing.

[0032] Fused Deposition Modeling (FDM) or Fused Filament Fabrication (FFF) as used herein involves building a part or article layer-by-layer by heating two or more thermoplastic materials to a semi-liquid state and extruding it according to computer-controlled paths. FDM can utilize a build material and optionally a support material. The modeling material (also referred to as the build material) forms the finished piece, and the support material forms scaffolding that can be washed away or dissolved when the process is complete. The process involves depositing material to complete each layer before the base moves down the Z-axis and the next layer begins.

[0033] As used herein, "build material" refers material forming the article to be printed, including the first polymeric material and second polymeric material. As used herein, "support material" refers to material used to hold up build material during the printing process that can be removed from the build material without or with minimal damage or effect to the printed article.

[0034] Selective Laser Sintering (SLS) involves sintering of very fine powders layer by layer from the bottom up until the product is completed. The process begins by the input of 3-D CAD files and, a control program converts the CAD files into instructions for controlling the layer by layer formation of the metal parts. The layer by layer formation is accomplished by laser sintering a first layer onto a platform. The platform then lowers and a fresh layer of powder is swept over the previously sintered layer, and the next layer is sintered or added on top of the previously built one. SLS can utilize a wide variety of materials including plastic, metal (direct metal laser sintering), ceramic, or glass powders. Unlike FDM or FFF, SLS does not require the use of a support material.

[0035] Stereolithography (SLA) uses a photopolymer resin that is selectively hardened by a laser beam delivering UV light at desirable spots on each thin resin layer. [0036] Digital Light Processing (DLP) exposes photopolymer filled with ceramic powder to light from a digital light processing (DLP) projector. The light hardens the mix materials and a layer of the object is therefore created. After every layer the Z-platform moves up and the lighting process for a new layer starts until the desired shape is formed.

[0037] 3D inkjet printing is a method for fabricating structures by selectively printing droplets of a build material onto a substrate in a build area. Polymers used in 3D inkjet printing can be dissolved in a solvent to adjust the solution viscosity for the inkjet process. Examples of inkjet printing include Poly Jet and MultiJet printing.

[0038] Depending on the additive process used, the mold inserts can be made from a variety of materials including polymeric materials, ceramics, glass, and metallic alloys.

[0039] The mold inserts can be printed with one or more materials that are compatible with each other in 3D printing processes. A first polymeric material can be a high heat polymeric material and can have a first melt-contacting surface that, when used in a mold insert, will be exposed to hot, injected, flowable polymeric materials. The recessed configuration of the first polymeric materials can be supported by other polymeric materials with the compressive strength, impact properties, and thermal resistance to withstand the high clamping tonnage and heat used in the molding process. By using such mold insert designs, resources and mold production times are reduced without loss of mold insert strength under injection pressure. The life of the mold inserts can almost double the life of silicon rubber molds and the number of parts produced can be much higher than for other prototyping methods.

[0040] Desirably, the design of the 3D printing process of the mold inserts can reduce or avoid the use of support materials by reducing or avoiding the use of geometries or features with less than a 45 degree angle. For instance, the mold inserts can be printed "upside-down" by first printing the first polymeric material and then the second polymeric material such that printing of the recessed configuration does not comprise printing features with less than a 45 degree angle.

[0041] Ejector holes can be formed in the mold inserts by creating holes smaller than the diameter of the ejector holes during the 3D printing process and then drilling and reaming the holes to achieve the tolerance to guide the ejector pins.

[0042] In addition to a reduction in the amount of material (e.g., high heat polymeric material) used, the methods described herein can result in a reduction of the thickness of the mold inserts as compared to the thickness of the same mold insert devoid of a press-facing surface with a recessed configuration. The thickness between a melt-contacting surface and a press-facing surface of a mold insert can be sufficient to provide structural rigidity to the mold insert. As used herein, "thickness" refers to the distance between two opposite surfaces, the melt-contacting surface and the press-facing surface, of the mold insert or the first polymeric material. The thickness can be 4 millimeters to 15 millimeters, or 4 millimeters to 10 millimeters. The thickness can be sufficient to mitigate or prevent heat transfer to and deformation or flow of the second polymeric material, which can have a lower glass transition temperature or melting point temperature than the first polymeric material.

[0043] A smallest dimension of a reinforcement structure (e.g., rib or boss) in a recessed configuration can be a width or diameter of 6 to 12 millimeters. The location and dimensions of the reinforcement (e.g., ribs) can be designed according to boundary conditions of the loading during the molding process. Structural simulations can be used to determine the location and dimensions of the reinforcement structures based on the size of the recessed configuration.

[0044] To increase the compressive strength of the mold insert, the first polymeric material and the second polymeric material can be printed along adjacent linear target roads, which can, for example, be greater than 0.1 millimeters wide, for example, 0.1 to 1.0 millimeters wide. It should be understood that the width of the target roads can be dependent on the additive manufacturing process (e.g., FDM, SLS, etc.) used. When using "big area" additive manufacturing (BAAM), where large scale structures are printed, the first polymeric material and the second polymeric material can be printed with a thickness, width, or both up to 10 millimeters.

[0045] The first polymeric material can be a polymer that has a glass transition temperature or melting point temperature that is greater than the temperature of the flowable polymeric material to be molded. For example, the polymer can be a thermoplastic having a glass transition temperature (T_g) of greater than or equal to 200°C, for example, greater than or equal 250°C, or 300 to 400°C.

[0046] Suitable materials for use as the first polymeric material include high heat polymeric materials such as imidazole polymers (e.g., polybenzimidazole), polyamides (e.g., high temperature nylons), polyamideimides, polyarylene ethers (e.g., polyphenylene ethers (PPE)), polyarylene sulfides (e.g., polyphenylene sulfides (PPS)), poly aryletherke tones, (e.g., polyether ether ketones), polyarylene ether sulfones (e.g., polyethersulfones (PES),

polyphenylene sulfones (PPS), and the like), polyimides (e.g., polyetherimides), or a combination comprising at least one of the foregoing. The foregoing polymers can be linear or branched, and can be homopolymers or copolymers, for example poly(etherimide-siloxane) or copolycarbonates containing two different types of carbonate units, for example bisphenol A units and units derived from a high heat monomer such as 3,3-bis(4-hydroxyphenyl)-2- phenylisoindolin-l-one. The copolymers can be random, alternating, graft, or block copolymers having two or more blocks of different homopolymers.

[0047] The first polymeric material can be a polyimide such as a polyetherimide and can have good impact. Polyetherimides included polyetherimide homopolymers and copolymers, for example polyetherimide sulfones and polyetherimide-siloxanes. Such polyetherimides are described, for example, in US 9,006,319, in WO 2009/10537, and in US 8937,127. In a specific embodiment the polyetherimide comprises units comprising bisphenol A moieties and moieties derived from p-phenylene diamine, m-phenylene diamine, sulfonyl dianiline, chemical equivalents of the foregoing diamines, or a combination comprising at least one of the foregoing diamines. The polyetherimides can have a melt index of 0.1 to 10 grams per minute (g/min), as measured by American Society for Testing Materials (ASTM) D1238 at 340 to 370 °C, using a 6.7 kilogram (kg) weight. In some embodiments, the polyetherimide polymer has a weight average molecular weight (Mw) of 1,000 to 150,000 grams/mole (Dalton), or 10,000 to 80,000 Daltons as measured by gel permeation chromatography, using polystyrene standards. Such polyetherimide polymers can have an intrinsic viscosity greater than 0.2 deciliters per gram (dl/g), or, more specifically, 0.35 to 0.7 dl/g as measured in m-cresol at 25°C.

[0048] Examples of other thermoplastic polymers that can be used as the first polymeric material include mixtures of polyimide with acrylonitrile-butadiene-styrene (ABS),

polycarbonate, polyetheretherketones, polyamides such as polyamide 6 or polyamide 66, and a combination comprising at least one of the foregoing.

[0049] The second polymeric material can be different from the first polymeric material. The second polymeric material can be any material compatible with the first polymeric material that, along with the first polymeric material, provides the physical properties (e.g., compression strength, impact strength, and thermal resistance to maintain the shape of the melt-contacting surface of the first polymeric material and resistance to flow under molding conditions) to allow for use of the mold inserts in molding articles.

[0050] The second polymeric material can be an epoxy material, with or without an adhesive to adhere the second polymeric material to the first polymeric material. The adhesive can be between the second polymeric material and the first polymeric material, or mixed with the second polymeric material. The second polymeric material can be a thermoplastic polymer.

[0051] The glass transition temperature of the second polymeric material can be less than the glass transition temperature of the first polymeric material. The second polymeric material can be a material other than a high heat polymeric material and the amount of high heat polymeric material used for making the mold insert can be reduced as compared to a mold insert of the same design made from only high heat polymeric materials. As such, the cost of the materials for producing the mold insert can be reduced.

[0052] The second polymeric material can further comprise thermoset polymers, metallic materials, natural materials such as cellulosic materials or fillers, or a combination comprising at least one of the foregoing.

[0053] The second polymeric material can comprise a material incompatible with the first polymeric material that, along with the first polymeric material, provides the physical properties (e.g., compression strength) to allow for use of the mold inserts in molding articles. As used herein, "incompatible" refers to a low affinity or lack of an ability for two materials to melt, mix, or adhere to one another. Such incompatible second polymeric materials can comprise a thermoplastic polymer, a thermoset polymer, a metallic material, a natural material, or a combination comprising at least one of the foregoing.

[0054] The second polymeric material can be assembled with the first polymeric material using mechanical locking, adhesive gluing, or both.

[0055] The second polymeric material can include various polymeric materials.

Polymeric materials can include polycarbonate, nylon, polyethylene, amorphous thermoplastics, thermoplastics, and thermosets. Some examples of thermoplastics include celluloid, cellulose acetate, ethylene-vinyl acetate (EVA), ethylene vinyl alcohol (EVOH), fluoroplastics (e.g., polychlorotrifluoroethylene (PCTFE)), ionomers, acrylic -polyvinyl chloride (Kydex™), liquid crystal polymer (LCP), polyacetal (POM or acetal), polyacrylates (acrylic), polyacrylonitrile (PAN or acrylonitrile), polyamide (PA or nylon), polyamide-imide (PAI), polybutadiene (PBD), polybutylene (PB), polycyclohexylene dimethylene terephthalate (PCT), polyester (e.g., polylactic acid (PLA), polycaprolactone (PCL), polyhydroxyalkanoates (PHAs), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), poly trime thy lene terephthalate (PTT)), polyethylene (PE), ketones (e.g., polyaryletherketone (PAEK), polyketone (PK),

polyetheretherketone (PEEK), polyetherketoneketone (PEKK)), polysulfone (PSU) (e.g., polyethersulfone (PES), polyphenylsulfone), polyethylenechlorinates (PEC), polyimide (PI) (e.g., polyetherimide (PEI)), polymethylpentene (PMP), polyphenylene ether (PPE), polyphenylene sulfide (PPS), polyphthalamide (PPA), polypropylene (PP), polystyrene (PS), polyure thane (PU), polyvinyl acetate (PVA), polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), acrylonitrile-butadiene-styrene (ABS), styrene-acrylonitrile (SAN), or a combination comprising at least one of the foregoing. The second polymeric material can comprise an acrylonitrile-butadiene-styrene.

[0056] Examples of thermoset materials can include unsaturated polyester, phenolic, epoxy, urethane, vinyl ester resins, or a combination comprising at least one of the forgoing.

[0057] Metals can be any metal available on the market including, but not limited to, powdered metals capable of being sintered and includes, but is not limited to, 303 stainless steel, 304 stainless steel, 431 stainless steel, 432 stainless steel, iron, copper, bronze, aluminum, tungsten, chromium-cobalt alloy, titanium and titanium alloys, or a combination comprising at least one of the foregoing. The metal can be incorporated into the second polymeric material, placed adjacent to the second polymeric material or the first polymeric material, or fused, adhered, or mechanically interlocked to the first polymeric material or the second polymeric material.

[0058] Alignment structures can be incorporated into the recessed configuration of the first polymeric material to facilitate alignment or attachment of the second polymeric material to the first polymeric material. For example, the second polymeric material can be a compressive support mechanically interlocked or adhered to the first press-facing surface. The compressive support can include a plurality of alignment holes aligned with ejector holes in the first polymeric material. The diameter of the alignment holes can be equal to or greater than 1.5 times a diameter of the ejector holes in the first polymeric material. There can be a plurality of ejector hole bosses in the recessed configuration of the first polymeric material adapted to insert into the alignment holes. In such a configuration, the ejector pins can be used without contacting the second polymeric material. Rather, the ejector holes in the first polymeric material can be used to guide the ejector pins.

[0059] The mold inserts described in the present disclosure can be used to produce articles. A method of forming an article can comprise aligning a cavity insert with a core insert to form a gap therebetween. The method can further comprise injecting a flowable polymeric material into the gap and solidifying the flowable polymeric material to form the article. The cavity insert and core insert can have a first press-facing surface and a second press-facing surface, respectively. The first press-facing surface, the second press-facing surface, or both can comprise a recessed configuration.

[0060] The method can further comprise applying a compression force equal to or greater than 1.5 meganewtons, for example, equal to or greater than 1.96 meganewtons, or equal to or greater than 2.66 meganewtons, or equal to or greater than 3.56 meganewtons, to the cavity insert and to the core insert during or after the step of injecting.

[0061] The cavity insert, the core insert, or both are adapted to mold a number of articles equal to or greater than 100 before failure, for example, 1,000 or more articles, or 2,000 or more articles, before failure. As used herein, "failure" refers to the deformation, cracking, or any other physical change in the mold inserts that results in molding of an article out of specification or an inability to mold an article.

[0062] The flowable polymeric material can be at any temperature suitable for flowing the polymeric material to be molded into the mold. As used herein "flowable" or "flowing" refers to the ability or act of moving a material in a fluid stream. The flowable polymeric material can be at a temperature equal to or greater than 100°C, for example, equal to or greater than 200°C, or equal to or greater than 300°C, or equal to or greater than 400°C.

[0063] The flowable polymeric material can be a material having a melting point temperature or T_g, that is 25°C less than the glass transition temperature of the first polymeric material. The flowable polymeric material comprises a homopolymer, copolymer, or a combination comprising at least one of the following materials: acrylonitrile-butadiene-styrene, acrylonitrile styrene acrylate, poly(Ci-6 alkyl)acrylate, polyacrylonitrile, polycarbonate, polyester, polybutylene terephthalate, poly(Ci-6 aikyl)methacrylate, poly(methyl methacrylate), polymethacrylamide, cyclic olefin polymer, polyolefin, polypropylene, polyethylene, polystyrene, vinyl polymer, and polyvinyl chloride.

[0064] A more complete understanding of the components, processes, and apparatuses disclosed herein can be obtained by reference to the accompanying drawings. These figures (also referred to herein as "FIG.") are merely schematic representations based on convenience and the ease of demonstrating the present disclosure, and are, therefore, not intended to indicate relative size and dimensions of the devices or components thereof and/or to define or limit the scope of the exemplary embodiments. Although specific terms are used in the following description for the sake of clarity, these terms are intended to refer only to the particular structure of the embodiments selected for illustration in the drawings, and are not intended to define or limit the scope of the disclosure. In the drawings and the following description below, it is to be understood that like numeric designations refer to components of like function.

[0065] As illustrated in FIG. 1A, core insert 10 comprises first polymeric material 12 and second polymeric material 14 adjacent to first polymeric material 12. First melt-contacting surface 16 can be made of first polymeric material 12. Ejector hole 18 can run through the central axis of core insert 10. Core insert 10 comprises a plurality of beads forming layers that are fused together.

[0066] As illustrated in FIG. IB, the cutout to view the cross section of core insert 10 shows first press-facing surface 17 of first polymeric material 12 comprises a recessed configuration. First polymeric material 12 comprises a thickness 19. Second polymeric material 14 is adjacent to first press-facing surface 17 of first polymeric material 12 and fills the recessed configuration of first polymeric material 12 to form second press-facing surface 15 of second polymeric material 14 with a planar configuration (e.g., a configuration devoid of recesses).

[0067] As illustrated in FIG. 2A, core insert 20 comprises first polymeric material 22 and second polymeric material 24. Core insert 20 comprise first melt-contacting surface 26.

[0068] However, as can be seen in the isometric view of core insert 20 in FIG. 2B and the bottom view of core insert 20 in FIG. 2C, second press-facing surface 28 of second polymeric material 24 comprises a recessed configuration comprising cavities 27, ribs 29, and a boss 30. By providing cavities 27, ribs 29, and a boss 30, the amount of second polymeric material 24 can be reduced as compared to the amount of second polymeric material 14 in core insert 10 while maintaining the physical properties (e.g., compression strength) for use of core insert 20 to mold an article. By printing core insert 20 "upside-down", production of core insert 20 can be performed in less time and with less material usage than production of core insert 10 with the same overall height and circumference dimensions.

[0069] As illustrated in FIG. 3A, cavity insert 40 comprises first polymeric material 42. As illustrated in FIG. 3B, a bottom view of cavity insert 40 shows press-facing surface 44 with a recessed configuration. The recessed configuration can include ribs 46 and cavities 48.

[0070] As illustrated in FIG. 4A, core insert 50 comprises first polymeric material 52. As illustrated in FIG. 4B, a bottom view of core insert 50 shows press-facing surface 54 with a recessed configuration. The recessed configuration can include ribs 56 and cavities 58.

[0071] As illustrated in FIG. 5 A, core insert 60 comprises first polymeric material 62 and second polymeric material 66. First polymeric material 62 can include press-facing surface 64 with a recessed configuration into which second polymeric material 66 is inserted. Second polymeric material 66 can be a compressive support including ejector holes 68. Article 69 can be injection molded using core insert 60 as one of the mold inserts.

[0072] Inserting second polymeric material 66 into the recessed configuration of first polymeric material 62 reduces the amount of first polymeric material 62 used to form core insert 60 as compared to a core insert of the same design formed using solely first polymeric material 62, which can be a high heat polymeric material. By providing second polymeric material 66 separately from first polymeric material 62, alternative second polymeric materials of different compositions or designs can be provided depending on the molding process used. Exemplary alternative designs for the compressive support are discussed further in reference to FIGs. 6 and 7A-B.

[0073] As illustrated in FIG. 5B, a top view of core insert 60 shows ejector holes 70 in first polymeric material 62. As seen in the cross-section A-A' view of core insert 60 illustrated in FIG. 5C, ejector holes 68 in second polymeric material 66 align with ejector holes 70 in first polymeric material 62. The corners of core insert 60 can be chamfered to improve the compression strength of core insert 60.

[0074] More than one material and other materials with different shapes and/or sizes (not illustrated) can be inserted into the recessed configuration of first polymeric material 62 to form a core insert.

[0075] As illustrated in FIG. 6, core insert 80 comprises first polymeric material 82 and second polymeric material 86. First polymeric material 82 can include press-facing surface 84 with a recessed configuration into which second polymeric material 86 is inserted. Second polymeric material 86 can include central ejector holes 88, peripheral ejector holes 88', and shared ejector holes 88" . In contrast to the ejector holes 68 of core insert 60, central ejector holes 88 are larger. Thus, a smaller amount of second polymeric material 86 is used to form core insert 80 as compared to the amount of second polymeric material 66 used to form core insert 60.

[0076] As illustrated in FIG. 7A, core insert 90 comprises first polymeric material 92 and second polymeric material 96. First polymeric material 92 can include press-facing surface 94 with a recessed configuration into which second polymeric material 96 is inserted. Press- facing surface 94 can include ejector hole bosses 95. Second polymeric material 96 can include ejector holes 98. As shown in FIG. 7B, a cross-sectional view of ejector hole bosses 95 fitting into second polymeric material 96, ejector holes 98 align with ejector hole bosses 95.

[0077] Mold inserts as described herein can be produced by selectively forming a first bead of a first polymeric material onto a first target road to form a plurality of first layers that fuse to form a first melt-contacting surface of the first polymeric material and a first press-facing surface of the first polymeric material opposite the first melt-contacting surface. For example, mold inserts as described herein can be produced by selectively extruding a first bead of a first polymeric material onto a first target road to form a plurality of first layers that fuse to form a first melt-contacting surface of the first polymeric material and a first press-facing surface of the first polymeric material opposite the first melt-contacting surface. Processes for producing the mold inserts can include three-dimensional printing processes such as fused deposition modeling, selective laser sintering, stereolithography, inkjet printing, or any other additive manufacturing process.

[0078] As illustrated in FIG. 8, method 100 for producing mold inserts at 102 forms a cavity insert by selectively extruding a first bead of a first polymeric material onto a first target road to form a plurality of first layers that fuse to form the cavity insert. The cavity insert can comprise a first melt-contacting surface and a first press-facing surface. At 104, the method can form a core insert by selectively extruding a second bead of a second polymeric material onto a second target road to form a plurality of second layers that fuse to form the core insert. The core insert can comprise a second melt-contacting surface and a second press-facing surface.

[0079] As illustrated in FIG. 9, an alternate method 200 for producing mold inserts at 202 forms a cavity insert by selectively extruding a first bead of a first polymeric material onto a first target road to form a plurality of first layers that fuse. The first polymeric material can comprise a first melt-contacting surface and a first press-facing surface. At 204, the method can form a core insert by selectively extruding a second bead of a second polymeric material onto a second target road to form a plurality of second layers that fuse. The second polymeric material can comprise a second melt-contacting surface and a second press-facing surface. At 206, the method can selectively extrude a third bead of a third polymeric material onto a third target road adjacent to the first press-facing surface of the first polymeric material to form a plurality of third layers that fuse. At 208, the method can selectively extruding a fourth bead of a fourth polymeric material onto a fourth target road adjacent to the second press-facing surface of the second polymeric material to form a plurality of fourth layers that fuse.

[0080] As illustrated in FIG. 10, another alternate method 300 for producing mold inserts at 302 forms a cavity insert with a recessed configuration by selectively extruding a first bead of a first polymeric material onto a first target road to form a plurality of first layers that fuse. The cavity insert can comprise a first melt-contacting surface and a first press-facing surface. At 304, the method can form a cavity insert compressive support by selectively extruding a second bead of a second polymeric material onto a second target road to form a plurality of second layers that fuse. At 306, the method can form a core insert with a recessed configuration by selectively extruding a third bead of a third polymeric material onto a third target road to form a plurality of third layers that fuse. The core insert can comprise a second melt-contacting surface and a second press-facing surface. At 308, the method can form a core insert compressive support by selectively extruding a fourth bead of a fourth polymeric material onto a fourth target road to form a plurality of fourth layers that fuse.

[0081] As illustrated at FIG. 11 , at 402, the cavity insert is aligned with to the core insert to form a gap therebetween. At 404, a flowable polymeric material can be injected into the gap. At 406, the flowable polymeric material solidifies to form the article. The first press-facing surface, the second press-facing surface, or both comprise a recessed configuration.

[0082] The foregoing methods can be used in applications, such as rapid prototyping applications, involving high temperature molding and/or production of a large number of prototypes. Other applications for the foregoing methods are where a limited number of articles will be produced.

[0083] This disclosure is further illustrated by the following examples, which are non- limiting.

EXAMPLES

Examples 1-2 and Comparative Examples A-B

[0084] In Example 1, a core insert with the design of core insert 10 illustrated in FIGs. 1 A-B was produced using a fused deposition modeling process. The first polymeric material was ULTEM™ 9085 polyetherimide and the second polymeric material was an acrylonitrile- butadiene-styrene (ABS). ULTEM™ 9085 polyetherimide is an amorphous polymer. The total thickness of the ULTEM™ 9085 polyetherimide was 10 millimeters (mm).

[0085] In Example 2, a cavity insert with the design of cavity insert 40 illustrated in FIGs. 3A-B and a core insert with the design of core insert 50 illustrated in FIGs. 4A-B were produced using a fused deposition modeling process and ULTEM™ 9085 polyetherimide. The total thickness of the ULTEM™ 9085 polyetherimide was 12 millimeters.

[0086] In Comparative Example A, the same core insert was made as in Example 1. The core insert was a single solid component formed of only with the ULTEM™ 9085

polyetherimide.

[0087] In Comparative Example B, the same mold inserts were made as in Example 2, except the recessed configuration (e.g., cavities) were filled with ULTEM™ 9085

polyetherimide.

[0088] The volumes of polyetherimide and acrylonitrile-butadiene-styrene used and the processing times are summarized in Table 1. Table 1

Example Material Volume Process Time

(kilograms) (hours)

Comparative Example A ULTEM™ 9085 polyetherimide 0.54 8

Example 1 ULTEM™ 9085 polyetherimide 0.1 1.5

ABS 0.45 4

Comparative Example B ULTEM™ 9085 polyetherimide 0.54 8

Example 2 ULTEM™ 9085 polyetherimide 0.254 4

Example 3 and Comparative Example C

[0089] In Example 3, a core insert with the design of core insert 60 illustrated in FIG. 5 A was produced using a fused deposition modeling process. The first polymeric material was ULTEM™ 9085 polyetherimide and the second polymeric material was acrylonitrile-butadiene- styrene. The overall dimensions of core insert 60 were 37 millimeters (mm) by 100 millimeters by 100 millimeters. The thickness of the ULTEM™ 9085 polyetherimide was 12 millimeters, except at the side walls, where the thickness was 4 millimeters, and at the portion with a projection, the thickness was 8 millimeters. The diameter of each of the 15 ejector holes in the ULTEM™ 9085 polyetherimide was 2.5 mm. The acrylonitrile-butadiene-styrene was 25 millimeters thick, 90 millimeters long, and 90 millimeters wide. The acrylonitrile-butadiene- styrene compressive support was 100% solid, and included 15 ejector holes having a diameter of 5 mm. The cavity insert was a tool steel cavity insert. The core insert and cavity insert were used to produce polypropylene articles. The core and cavity were aligned for form a gap.

Polypropylene was heated to 200°C and injected into the gap. A pressure of 40 MegaPascals was maintained to provide 1 meganewtons of compressive force for 150 seconds during the injecting. Once the article cooled to below 70°C, the mold was opened by separating the core insert and the cavity insert. Then the ejector pins pushed the final article away from the core insert. The number of polypropylene articles that could be printed with core insert 60 was at least 150.

[0090] In Comparative Example C, the same core insert was made as in Example 3, except acrylonitrile-butadiene-styrene was replaced with ULTEM™ 9085 polyetherimide and the core insert was produced in one piece. The number of polypropylene articles that could be printed with core insert 60 was at least 150.

[0091] The volumes of polyetherimide and ABS polymer used and the processing times are summarized in Table 2. Table 2

Example Material Weight Process Time

(grams) (hours)

Comparative Example C ULTEM™ 9085 polyetherimide 332 7

Example 3 ULTEM™ 9085 polyetherimide 162 5

ABS 120 2

Examples 4 and 5

[0092] In Example 4, a core insert with the design of core insert 80 illustrated in FIG. 6 was produced using a fused deposition modeling process. The first polymeric material was ULTEM™ 9085 polyetherimide and the second polymeric material was acrylonitrile-butadiene- styrene. The weight of material used was 157.3 grams of polyetherimide and 190 grams of acrylonitrile-butadiene-styrene. The overall dimensions of core insert 80 were 37 millimeters by 100 millimeters by 100 millimeters. The thickness of the ULTEM™ 9085 polyetherimide was 8 millimeters, except at the sidewalls, where the thickness was 4 millimeters, and at the portion with a projection, the thickness was 8 millimeters. The diameter of the 15 ejector holes in the ULTEM™ 9085 polyetherimide was 2.5 millimeters. The acrylonitrile-butadiene-styrene was 29 millimeters thick, 95 millimeters long, and 88 millimeters wide. The acrylonitrile-butadiene- styrene was 100% solid, and included 6 central ejector holes 88 with a diameter of 10 millimeters, 5 peripheral ejector holes 88' with a diameter of 5 millimeters, and 2 shared ejector holes 88" with a height from the base to the apex of 10 millimeters and a width of 10 millimeters. The cavity insert was with a tool steel cavity insert. The number of polypropylene articles that could be printed with core insert 80 was at least 150.

[0093] In Example 5, a core insert with the design of core insert 90 illustrated in FIG. 7A was produced using a fused deposition modeling process. The first polymeric material was ULTEM™ 9085 polyetherimide and the second polymeric material was acrylonitrile-butadiene- styrene. The overall dimensions of core insert 90 were 37 millimeters by 100 millimeters by 100 millimeters. The thickness of the first polymeric material ranged from 4 millimeters to 10 millimeters, depending on the features present (e.g., ejector hole bosses). The side wall thickness was 4 millimeters, and at the portion with a projection, the thickness was 8 millimeters. The ejector hole bosses were a length 2 times the diameter of the ejector holes and a diameter 1.5 times the diameter of the ejector holes. The diameter of the 15 ejector holes in the ULTEM™ 9085 polyetherimide was 2.5 millimeters. The acrylonitrile-butadiene-styrene was 33 millimeters thick, 95 millimeters long, and 88 millimeters wide. The acrylonitrile- butadiene-styrene was 100% solid, and included 15 ejector holes having a diameter of 2.5 millimeters. The cavity insert was a tool steel cavity insert.

[0094] The weight of material used was 113 grams of polyetherimide and 238 grams of acrylonitrile-butadiene-styrene. The number of polypropylene articles that could be printed with core insert 90 was at least 450.

[0095] By utilizing the designs illustrated in FIGs. 6 and 7A, the amount of

polyetherimide used was further reduced.

[0096] Thus, the methods and mold inserts avoid using large amounts of high heat polymeric materials while maintaining the physical properties needed for the molding processes used (e.g., compression strength, impact strength, or thermal resistance to maintain the shape and resist deformation or flow of the polymeric material of the mold insert). This result is achieved by using high heat polymeric materials for the first polymeric material comprising a melt-contacting surface and a recessed configuration with ribs, honeycomb structures, or bosses on a press-facing surface of the mold insert in order to provide greater strength to withstand high injection or compression pressures during the molding process. A recessed configuration or use of materials that can be extruded at faster rates than high heat polymeric materials can also result in shorter manufacturing times.

[0097] The compositions and methods disclosed herein are further illustrated by the following embodiments, which are non-limiting:

[0098] Embodiment 1 : A method for making a mold insert comprising: selectively forming a first bead of a first polymeric material onto a first target road to form a plurality of first layers that fuse to form a first melt-contacting surface of the first polymeric material and a first press-facing surface of the first polymeric material opposite the first melt-contacting surface, wherein the first polymeric material comprises a high heat polymeric material, and wherein the first press-facing surface comprises a recessed configuration.

[0099] Embodiment 2: The method of Embodiment 1, wherein a glass transition temperature of the high heat polymeric material is greater than or equal to 200°C or a melting point temperature of the high heat polymeric material is greater than or equal to 200°C.

[0100] Embodiment 3: The method of any one or more of the preceding embodiments, wherein the high heat polymeric material comprises an imidazole polymer, polyamide, polyamideimide, polyaryletherketones, polyarylene ether, polyarylene sulfide, polyarylene ether sulfone, polyimide, or a combination comprising at least one of the foregoing. [0101] Embodiment 4: The method of Embodiment 3, wherein the polyimide is a polyetherimide.

[0102] Embodiment 5: The method of any one or more of the preceding embodiments, wherein a thickness of the first polymeric material between the first melt-contacting surface and the first press-facing surface is 4 millimeters to 15 millimeters.

[0103] Embodiment 6: The method of any one or more of the preceding embodiments, wherein the recessed configuration comprises a cavity, a rib, a honeycomb, a boss, or a combination comprising at least one of the foregoing.

[0104] Embodiment 7: The method of Embodiment 6, wherein a width of the rib or the honeycomb is equal to or greater than 6 millimeters.

[0105] Embodiment 8: The method of any one or more of the preceding embodiments, further comprising selectively forming a second bead of a second polymeric material onto a second target road adjacent to the first press-facing surface to form a plurality of second layers that fuse.

[0106] Embodiment 9: The method of Embodiment 8, wherein the second polymeric material comprises an acrylonitrile-butadiene-styrene, celluloid, cellulose acetate, ethylene-vinyl acetate, ethylene vinyl alcohol, fluoroplastics, ionomers, acrylic -polyvinyl chloride, liquid crystal polymer, polyacetal, polyacrylates, polyacrylonitrile, polyamide, polyamide-imide, polybutadiene, polybutylene, polycyclohexylene dimethylene terephthalate, ketones, polyester, polyethylene, polysulfone, polyethylenechlorinates, polyimide, polymethylpentene, polyphenylene ether, polyphenylene sulfide, polyphthalamide, polypropylene, polystyrene, polyurethane, polyvinyl acetate, polyvinyl chloride, polyvinylidene chloride, styrene- acrylonitrile, or a combination comprising at least one of the foregoing.

[0107] Embodiment 10: A mold insert made by the method of any one or more of Embodiments 1 to 9.

[0108] Embodiment 11 : The mold insert of Embodiment 10, wherein the second polymeric material is a compressive support mechanically interlocked or adhered to the first press-facing surface. [0109] Embodiment 12: A method for producing an article comprising: aligning the mold insert of any one of Embodiments 10 to 11 with a cavity insert or a core insert to form a gap therebetween; injecting a flowable polymeric material into the gap; and solidifying the flowable polymeric material to form the article.

[0110] Embodiment 13: The method of any one or more of the preceding embodiments, wherein the mold insert is adapted to withstand a compression force equal to or greater than 1.5 meganewtons.

[0111] Embodiment 14: The method of any one or more of the preceding embodiments, wherein the mold insert is adapted to mold a number of articles equal to or greater than 100 before failure.

[0112] Embodiment 15: The method of any one or more of the preceding embodiments, wherein the mold insert is adapted to withstand molding pressures of 1.5 to 2 meganewtons for at least 3,000 molding cycles.

[0113] Embodiment 16: The method of any one or more of the preceding embodiments, wherein the mold insert is adapted to mold a flowable polymeric material at a temperature equal to or greater than 100°C.

[0114] Embodiment 17: The method of any one or more of Embodiments 12 to 16, wherein the method comprises injection molding, blow molding, thermoforming, or compression molding.

[0115] Embodiment 18: The method of any one or more of Embodiments 12 to 17, wherein the cavity insert or the core insert comprises: a plurality of layers of a third polymeric material comprising a high heat polymeric material, and wherein the third polymeric material comprises a third melt-contacting surface and a third press-facing surface opposite the third melt-contacting surface, and wherein the third press-facing surface comprises a recessed configuration.

[0116] Embodiment 19: The method of Embodiment 18, wherein the cavity insert or the core insert comprises a fourth polymeric material adjacent to the third press-facing surface of the third polymeric material.

[0117] Embodiment 20: The method of any one or more of Embodiments 12 to 19, wherein the flowable polymeric material comprises a homopolymer, copolymer, or a combination comprising at least one of an acrylonitrile-butadiene-styrene, acrylonitrile styrene acrylate, poly(Ci-6 alkyl)acrylate, polyacrylonitrile, polycarbonate, polyester, polybutylene terephthalate, poly(Ci-6 aikyl)methacrylate, poly(methyl methacrylate), polymethacrylamide, cyclic olefin polymer, polyolefin, polypropylene, polyethylene, polystyrene, vinyl polymer, and polyvinyl chloride.

[0118] The compositions, methods, and articles can alternatively comprise, consist of, or consist essentially of, any appropriate materials, steps, or components herein disclosed. The compositions, methods, and articles can additionally, or alternatively, be formulated so as to be devoid, or substantially free, of any materials (or species), steps, or components, that are otherwise not necessary to the achievement of the function or objectives of the compositions, methods, and articles.

[0119] All ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other (e.g., ranges of "up to 25 wt.%, or, more specifically, 5 wt.% to 20 wt.%", is inclusive of the endpoints and all intermediate values of the ranges of "5 wt.% to 25 wt.%," etc.). "Combinations" is inclusive of blends, mixtures, alloys, reaction products, and the like. The terms "first," "second," and the like, do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The terms "a" and "an" and "the" do not denote a limitation of quantity, and are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. "Or" means "and/or" unless clearly stated otherwise. Reference throughout the specification to "some embodiments", "an embodiment", and so forth, means that a particular element described in connection with the embodiment is included in at least one embodiment described herein, and may or may not be present in other embodiments. In addition, it is to be understood that the described elements may be combined in any suitable manner in the various embodiments.

[0120] Unless specified to the contrary herein, all test standards are the most recent standard in effect as of the filing date of this application, or, if priority is claimed, the filing date of the earliest priority application in which the test standard appears.

[0121] Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one of skill in the art to which this application belongs. All cited patents, patent applications, and other references are incorporated herein by reference in their entirety. However, if a term in the present application contradicts or conflicts with a term in the incorporated reference, the term from the present application takes precedence over the conflicting term from the incorporated reference.

[0122] While particular embodiments have been described, alternatives, modifications, variations, improvements, and substantial equivalents that are or may be presently unforeseen may arise to applicants or others skilled in the art. Accordingly, the appended claims as filed and as they may be amended are intended to embrace all such alternatives, modifications variations, improvements, and substantial equivalents.

[0123] What is claimed is:

Claims

1. A method for making a mold insert comprising:

selectively forming a first bead of a first polymeric material onto a first target road to form a plurality of first layers that fuse to form a first melt-contacting surface of the first polymeric material and a first press-facing surface of the first polymeric material opposite the first melt-contacting surface, wherein the first polymeric material comprises a high heat polymeric material, and

wherein the first press-facing surface comprises a recessed configuration.

2. The method of Claim 1 , wherein a glass transition temperature of the high heat polymeric material is greater than or equal to 200°C or a melting point temperature of the high heat polymeric material is greater than or equal to 200°C.

3. The method of any one or more of the preceding claims, wherein the high heat polymeric material comprises an imidazole polymer, polyamide, polyamideimide, polyarylene ether, polyarylene sulfide, polyaryletherketones, polyarylene ether sulfone, polyimide, or a combination comprising at least one of the foregoing.

4. The method of Claim 3, wherein the polyimide is a polyetherimide.

5. The method of any one or more of the preceding claims, wherein a thickness of the first polymeric material between the first melt-contacting surface and the first press-facing surface is 4 millimeters to 15 millimeters.

6. The method of any one or more of the preceding claims, wherein the recessed configuration comprises a cavity, a rib, a honeycomb, a boss, or a combination comprising at least one of the foregoing.

7. The method of Claim 6, wherein a width of the rib or the honeycomb is equal to or greater than 6 millimeters.

8. The method of any one or more of the preceding claims, further comprising selectively forming a second bead of a second polymeric material onto a second target road adjacent to the first press-facing surface to form a plurality of second layers that fuse.

9. The method of Claim 8, wherein the second polymeric material comprises an acrylonitrile-butadiene-styrene, celluloid, cellulose acetate, ethylene-vinyl acetate, ethylene vinyl alcohol, fluoroplastics, ionomers, acrylic-polyvinyl chloride, liquid crystal polymer, polyacetal, polyacrylates, polyacrylonitrile, polyamide, polyamide-imide, polybutadiene, polybutylene, polycyclohexylene dimethylene terephthalate, ketones, polyester, polyethylene, polysulfone, polyethylenechlorinates, polyimide, polymethylpentene, polyphenylene ether, polyphenylene sulfide, polyphthalamide, polypropylene, polystyrene, polyurethane, polyvinyl acetate, polyvinyl chloride, polyvinylidene chloride, styrene-acrylonitrile, or a combination comprising at least one of the foregoing.

10. A mold insert made by the method of any one or more of Claims 1 to 9.

11. The mold insert of Claim 10, wherein the second polymeric material is a compressive support mechanically interlocked or adhered to the first press-facing surface.

12. A method for producing an article comprising,

aligning the mold insert of any one of Claims 10 to 11 with a cavity insert or a core insert to form a gap therebetween;

injecting a flowable polymeric material into the gap; and

solidifying the flowable polymeric material to form the article.

13. The method of any one or more of the preceding claims, wherein the mold insert is adapted to withstand a compression force equal to or greater than 1.5 meganewtons.

14. The method of any one or more of the preceding claims, wherein the mold insert is adapted to mold a number of articles equal to or greater than 100 before failure.

15. The method of any one or more of the preceding claims, wherein the mold insert is adapted to withstand molding pressures of 1.5 to 2 meganewtons for at least 3,000 molding cycles.

16. The method of any one or more of the preceding claims, wherein the mold insert is adapted to mold a flowable polymeric material at a temperature equal to or greater than 100°C.

17. The method of any one or more of Claims 12 to 16, wherein the method comprises injection molding, blow molding, thermoforming, or compression molding.

18. The method of any one or more of Claims 12 to 17, wherein the cavity insert or the core insert comprises:

a plurality of layers of a third polymeric material comprising a high heat polymeric material, and

wherein the third polymeric material comprises a third melt-contacting surface and a third press-facing surface opposite the third melt-contacting surface, and

wherein the third press-facing surface comprises a recessed configuration.

19. The method of Claim 18, wherein the cavity insert or the core insert comprises a fourth polymeric material adjacent to the third press-facing surface of the third polymeric material.

20. The method of any one or more of Claims 12 to 19, wherein the flowable polymeric material comprises a homopolymer, copolymer, or a combination comprising at least one of an acrylonitrile-butadiene-styrene, acrylonitrile styrene acrylate, poly(Ci-6 alkyl)acrylate, polyacrylonitrile, polycarbonate, polyester, polybutylene terephthalate, poly(Ci-6

aikyl)methacrylate, poly(methyi methacrylate), polymethacrylamide, cyclic olefin polymer, polyolefin, polypropylene, polyethylene, polystyrene, vinyl polymer, and polyvinyl chloride.