Injection Molding Using 3D Printed Tooling
Category
Sciences and Technology
Department
Plastics Engineering Technology
Student Status
Undergraduate
Research Advisor
Mr. Dan Spielbusch, Dr. Jeanne Norton
Document Type
Event
Location
Student Center Ballroom
Start Date
10-4-2025 2:00 PM
End Date
10-4-2025 4:00 PM
Description
Injection molding has traditionally used steel tooling and inserts to manufacture parts. With the rapid development of 3D printing, injection molding tooling is changing. 3D printing, or additive manufacturing, is a process of making three dimensional objects from a digital file and is the opposite of traditional subtractive manufacturing, or hollowing out a block of material with a milling machine. Plastics manufacturers have utilized 3D printing in order to produce molds at reduced material cost, fabrication time, and energy input. Our preliminary review of current technology allowed us to determine an effective method of replicating this process in the PSU Plastics labs. After designing parts, we modeled inserts for the A- and B-half of the mold in SolidWorks, our computer aided design software. From these designs, and information from the 3D printer, we used a FormLabs Form 3+ printer with High Temp liquid resin to 3D print mold inserts. We encountered material challenges due to material weight causing creep during the printing process. To avoid this issue, we designed inserts to fill in the back of the pocket. After printing, the inserts and spacers were test-fitted into the mold base and sanded to fit snuggly within the pockets. Most of our printed parts have been produced successfully with slight adjustments and reprints of certain component to insure the best fit. Once 3D printed inserts are fitted in the mold base, we will produce parts with 3D printed tooling on the Arburg injection molding machine and evaluate part quality.
Injection Molding Using 3D Printed Tooling
Student Center Ballroom
Injection molding has traditionally used steel tooling and inserts to manufacture parts. With the rapid development of 3D printing, injection molding tooling is changing. 3D printing, or additive manufacturing, is a process of making three dimensional objects from a digital file and is the opposite of traditional subtractive manufacturing, or hollowing out a block of material with a milling machine. Plastics manufacturers have utilized 3D printing in order to produce molds at reduced material cost, fabrication time, and energy input. Our preliminary review of current technology allowed us to determine an effective method of replicating this process in the PSU Plastics labs. After designing parts, we modeled inserts for the A- and B-half of the mold in SolidWorks, our computer aided design software. From these designs, and information from the 3D printer, we used a FormLabs Form 3+ printer with High Temp liquid resin to 3D print mold inserts. We encountered material challenges due to material weight causing creep during the printing process. To avoid this issue, we designed inserts to fill in the back of the pocket. After printing, the inserts and spacers were test-fitted into the mold base and sanded to fit snuggly within the pockets. Most of our printed parts have been produced successfully with slight adjustments and reprints of certain component to insure the best fit. Once 3D printed inserts are fitted in the mold base, we will produce parts with 3D printed tooling on the Arburg injection molding machine and evaluate part quality.
