Luís M. Durão, André F. V. Pedroso, R.P. Martinho, Marlene Brito, Ricardo J. D. Alexandre, Angelos P. Markopoulos
Injection Moulding (IM) tools play a decisive role in high-volume manufacturing, particularly in the production of polymer components where dimensional accuracy, surface integrity, and process stability are paramount. The increasing adoption of fibre-reinforced polymers (FRPs), especially within the automotive and aerospace sectors, has substantially intensified the mechanical, thermal, and tribological demands imposed on tooling systems, thereby accelerating Tool Wear (TW) and surface degradation. Comparable challenges are encountered in related forming processes, including sheet-metal stamping and pressing, where abrasive contact, cyclic loading, and elevated temperatures contributepractical to premature tool failure. Extending tool service life has consequently emerged as a strategic priority for improving cost efficiency, reducing unplanned downtime, and ensuring consistent product quality across extended production runs. Against this background, the present review critically evaluates recent technological advances aimed at enhancing the durability and operational longevity of injection moulding tools, with a particular focus on solutions that have demonstrated practical relevance under industrial conditions. Advanced surface-engineering approaches, including electrodeposition, nitriding, and physical and chemical vapour deposition (PVD and CVD) coatings, are examined in terms of their effectiveness in mitigating wear, corrosion, and thermal-fatigue damage. Developments in tool material selection, encompassing high-performance alloys and engineered coating systems, are assessed with respect to friction reduction and thermal management, providing actionable insights for tool designers and manufacturing engineers. In addition, the integration of additive manufacturing for tool repair and refurbishment is discussed as a pragmatic and increasingly viable route to extending Tool Lifespan (TL), supporting more sustainable and cost-effective tooling strategies in modern manufacturing environments.