Micro-Architected Lattice-Based Mesh for Fiber Filters: A Novel Additive Manufacturing Architecture for Molded Fiber Tooling

Promising developments have shown the untapped potential of additive manufacturing (AM) for fabricating molded fiber molds (MFM), a critical piece for the molded fiber industry. This work builds upon AM implementations, presenting a novel application of micro-architected lattice structure to construct fiber filtering meshes attached to drainage channels, all combined in an “Integrated Mold.” Current AM approaches have failed to build low-cost and high lifespan tools. Instead, their design approach imitates the existing MFM structure, covering a base-shaped structure with a mesh. The main disadvantage of this method is the trade-off between water drainage and stiffness. Lattice materials have shown the capability of building porous structures with high stiffness, strength-to-weight ratio, fatigue tolerance, and the capacity to control the flow of fluids. The methodology presented in this research defines a new approach for MFM design that provides a broader range of porosity and enhances water drainage capabilities without affecting structural performance. As a result, it retrieves enhanced control over the physical properties of MFM. The studies presented in this paper show the functionality of lattice structures as filters for solid particles. Moreover, it offers an immediate application of this technology. The tools developed in this research have validated their capability to withstand more than a hundred cycles as tooling for MFP, proving their functionality for prototyping stages. This result seeks to accelerate the expansion of an industry that capitalizes on locally abundant, biodegradable, and recyclable raw materials.