Development of High-Temperature-Resistant DLP 3D Printed Molds for Carbon Fiber Lamination in Autoclave Processes: Applications in Customized and Structural Components

This work investigates the potential of additive manufacturing (AM) as a cost- and time effective alternative for producing molds suitable for autoclave curing of carbon fiber prepregs laid up manually. The study focuses on two application domains: biomedical devices and structural components. The methodology combines CAD-based mold design, digital light processing (DLP- LCD) 3D printing, manual lamination of prepregs, autoclave curing, and final evaluation of the mold’s performance. The results highlight the viability of AM for low-volume, customized production- especially in biomedical applications, where geometrical complexity and personalization are key. In this context, the printed molds demonstrated excellent thermal resistance and dimensional accuracy, proving fully compatible with the curing process. However, for structural components requiring higher dimensional stability and repeatability across multiple curing cycles, limitations emerged. In particular, when the mold could not be printed as a single monolithic part due to size constraints, deformation occurred at the joint interfaces. This was caused by the non-uniform release of residual stresses during the autoclave cycle, which compromised the alignment and reusability of the mold. These issues were further exacerbated by the larger dimensions and structural function of the part, highlighting the need for improved joint design and stress management in modular molds. From a scientific and industrial perspective, this approach shows strong promise as a prototyping tool, offering fast iteration and design validation. Future research should address mold modularity, stress-relief strategies, and the long-term reliability of printed molds under repeated thermal cycles to enable broader adoption in high-performance composite manufacturing.