Depending on the geometry and the size, multiple molds can be printed at once on a build platform to increase printing efficiency.

Safety in plastic injection molding is crucial for protecting workers and ensuring efficient production. Due to the high temperatures and heavy machinery involved, taking appropriate safety measures is essential. From using personal protective equipment to knowing emergency shutdown procedures, each step helps create a safe working environment.

Adding two to five degrees of draft on surfaces perpendicular to the direction of pull will allow the part to be removed more easily and will minimize degradation of the mold.

Rigid 10K Resin is an industrial-grade, highly glass-filled material, which provides a solution that can cope with a wider variety of geometries and injection molding processes. It has an HDT of 218°C @ 0.45 MPa and a tensile modulus of 10,000 MPa, making it strong, extremely stiff, and thermally stable.

If you have more questions about the workflow, make make sure to check our article FAQ: Injection Molding With 3D Printed Molds.

Injection molding is ubiquitous as a manufacturing process—in fact, the majority of plastic products in the world today are manufactured by injection molding. While it is an ideal technique for large-scale production needs, traditional CNC machined metal molds have prohibitive high costs and long lead times for low-volume production.

A high-performance desktop SLA 3D printer, like the Formlabs’ Form 3. The Form 3 can produce accurate molds with crisp features, and a smooth surface finish that will yield high-quality final molded parts. Beyond DIY injection molding, an SLA 3D printer is also a valuable asset for prototyping and other applications throughout product development.

The exact approach to DIY injection molding will vary based on your desired design and volume, but these tips and tricks will help increase your success rate.

The conversation around 3D printing and injection molding is often oppositional, but it’s not always a question of one versus the other. By directly 3D printing parts or using 3D printed molds for injection molding for prototyping and low-volume production, you can leverage the benefits of both technologies. This will make your manufacturing process more time- and cost-efficient and allow you to bring products to the market faster.

Turn the visibility of your current mold core off, and turn the other side on. Repeat the process to ensure that the object fully intersects with the inlet of the other half of the mold core. With your object lined up, you’re ready to subtract the area of two intersecting objects by using the “boolean difference” function in Blender.

Depending on the injected material, adhesion of the part to the mold can cause deterioration of the mold during extraction, in particular with flexible materials such as TPUs or TPEs. Using a mold release agent is a good solution to help separate the part from the mold. Silicone mold release agents are compatible with Formlabs Grey Pro Resin, High Temp Resin, and Rigid 10K Resin.

Select the first half of your object, and choose the boolean option under the Modifiers Menu. Select the object you’re cutting, and make sure that the “difference” operation is selected. Apply the operator, and do the same for the other side. It should look something like the image below. If you get stuck here, this tutorial on adding interlocking components to a design may be helpful.

Sound View Plastics brings over 30 years of diverse experience to the plastics industry. We’re prepared to assist you with part, assembly, and product designs to complete your next injection molding project. Our robust industry network, trusted quality processes, and tool development can help your business be more efficient. Sound View is ready to be your partner in plastics.

First, pick the CAD software tool of your preference to design the mold insert. We’ll use the open-source Blender, but the workflow should be fairly similar in any other CAD software.

Knowing how to quickly and safely shut down machinery in an emergency is essential in any plastic injection molding facility. Emergency shutdown procedures should be clearly outlined and accessible to all employees. Specific buttons or levers on the machines can immediately stop operations if a hazardous situation arises. Regular drills and training on emergency shutdowns ensure that workers can act swiftly and correctly when needed. This proactive approach can prevent accidents and reduce the severity of any incidents, making the workplace safer for everyone.

If designing for an aluminum mold frame, add .125 mm of extra thickness to the back of the mold plates to account for compression forces and to ensure a complete seal.

Wearing the right personal protective equipment (PPE) is vital in plastic injection molding. Workers should always wear safety glasses to protect their eyes from debris and possible splashes of hot material. Heat-resistant gloves are essential, as they shield hands from high temperatures encountered during the process. Additionally, wearing long sleeves and pants made of non-flammable materials can offer extra protection. Ear protection is also a good idea in noisy environments to prevent hearing damage. Using PPE correctly helps reduce the risk of injuries and keeps workers safe on the job.

Proper training and safety drills form the backbone of a safe workplace. Employees should receive comprehensive training on operating machines, handling materials, and following emergency procedures. New hires must be thoroughly educated before beginning their duties, and ongoing training sessions ensure that all staff remain current on safety protocols. Conducting regular safety drills helps reinforce training and prepare employees for real-life emergencies. A well-trained workforce is essential for minimizing risks and maintaining a safe and productive workplace.

High Temp Resin offers a heat deflection temperature is 238 °C @ 0.45 MPa that is suitable for injection molding. This material is more brittle, but is recommended for materials with a high molding temperature and to reduce cooling time.

A 3D printing material that can withstand the temperature and pressure on the mold during the injection molding process. We recommend the following materials for Formlabs SLA 3D printers:

Based on internal testing and case studies with our customers, we suggest to choose the 3D printing resin based on the criteria from the table below. Three stars means the resin is highly effective, one star is less effective.

Download our white paper for guidelines for using 3D printed molds in the injection molding process to lower costs and lead time and see real-life case studies with Braskem, Holimaker, and Novus Applications.

Now that you’ve designed and 3D printed your mold, you can mold the parts on your benchtop plastic injection molding machine.

Consider the desired properties of your object and the capabilities of your injection molder before you make your choice. From there, simply follow the bespoke instructions on your injection molder to quickly and efficiently produce your parts.

Creating custom molds using a stereolithography (SLA) 3D printer, like the Form 3, is simple and convenient, allowing you to leverage the benefits of both 3D printing and traditional molding techniques.

You have a wide variety of materials to choose from for injection molding. Formlabs and our customers have tested the following materials with 3D printed injection molds:

Regular maintenance and inspections of injection molding equipment play a significant role in workplace safety. Machines should be routinely checked for signs of wear, damage, or other issues that could lead to malfunctions or accidents. Scheduled maintenance helps ensure that all components are operating correctly and can prevent unexpected breakdowns. Inspection routines should include checking electrical systems, hydraulic lines, and safety guards. By keeping machinery in top condition, we can maintain a safer and more reliable production environment.

Proper handling of materials is another fundamental safety practice. Workers should be trained to move and store raw materials safely to avoid spills and injuries. It’s crucial to follow guidelines for lifting heavy bags of plastic pellets or other materials to prevent back injuries. When dealing with chemicals or additives, using appropriate containers and labeling can help avoid mishandling and accidents. Keeping the work area clean and organized also contributes to a safer environment. Safe handling practices ensure that materials are used efficiently and safely, reducing potential hazards in the workplace.

To 3D print the mold, it’s essential to pick a material that can withstand the temperature and pressure on the mold during the injection molding process.

In this guide, we’ll walk you through the process of DIY injection molding and share all the tools and tips necessary to utilize plastic injection molding in-house using 3D printed molds.

By focusing on these safety aspects, companies can safeguard their employees and maintain high standards of productivity. Keeping everyone informed and prepared is key to successful plastic injection molding.

A benchtop injection-molding machine, such as the Galomb Model-B100 or the Holipress. There are a number of benchtop injection molders on the market that vary in cost. Many of the lower cost molders use a hand-driven plunger, while some of the more expensive units use a screw or pneumatic system. Some of our customers have recommended systems from Minijector, Morgan, APSX, or Micromolder as well. Desktop automated molders such as the product line from Babyplast are good alternatives for mass production of small parts.

Grey Pro Resin has a lower thermal conductivity than High Temp Resin or Rigid Resin, which leads to a longer cooling time, but it is softer and can wear hundreds of cycles.

Interested in other applications of 3D printed molds? Download our white paper that also covers thermoforming and casting with elastomers.

Building a setup for DIY injection molding does require some investment. It takes both money and time to acquire the right equipment and to master using it. However, these costs are in many cases still lower than the cost of a single metal mold, so the eventual time and cost savings, once you’re up and running, will easily offset the initial effort.

Now, you can position your mold. Ensure that the object fully intersects with the inlet for the molten plastic during the injection molding process. Use orthographic mode, engaged via “toggle perspective/ortho,” to make this more straightforward.

Want to learn more about injection molding with 3D printed molds? Download our white paper for detailed guidelines for using 3D printed molds in the injection molding process and see real-life case studies with Braskem, Holimaker, and Novus Applications.

Setting up the print only takes a few seconds in PreForm, the print preparation software for Formlabs 3D printers. If your mold design requires support structures for printing, make sure to orient the mold halves in PreForm so that the cavity faces up. This will simplify post-processing and ensure a high-quality surface for your molded parts.

In Blender, use the eye icon in the scene explorer to toggle off one half of the mold. Once your workspace is set up to your liking, set both halves of the mold to the “wire” draw type under the Object menu, as in the image below.

Stay updated with the latest 3D printing news, interviews with experts from around the world and tutorials on how to leverage 3D printing.

Understanding and implementing safety measures in plastic injection molding is crucial for protecting workers and ensuring effective operations. From wearing appropriate PPE to conducting thorough training and maintenance, each step minimizes risks and enhances safety. Keeping these practices in mind helps create a secure environment where everyone can work efficiently and confidently.

To reduce the visibility of print lines on the finished part, print the mold with a smaller layer height (50 or 25 microns per layer instead of the default 100). Note that this increases print time.

Machine guarding is a crucial part of safety in plastic injection molding. Guards on the machines prevent workers from coming into contact with moving parts. These guards should always be in place and never removed during operation. It’s important for operators to check that all safety guards are secured before starting the machine. Regular inspections can ensure that guards are functioning properly and haven’t been tampered with. Good machine guarding practices help prevent accidents and make the workplace safer.

Before purchase, make sure to evaluate the injection molder carefully against your production requirements. For large parts, industrial processes will still be necessary. This DIY injection molding technique is best optimized for producing small parts at low volumes.

Having a clear understanding of both basic and advanced safety tips can prevent accidents and keep operations running smoothly. Fundamental practices include wearing the right gear, properly handling materials, and ensuring machine guards are in place. Additionally, workplace-specific measures like regular maintenance and thorough employee training boost overall safety.

For prototyping and low-volume production (approximately 10-1000 parts), 3D printed injection molds provide a time- and cost-efficient solution. They also enable a more agile manufacturing approach, allowing engineers and designers to test mold designs, easily modify them, and then continue to iterate on their designs much faster, while being orders of magnitude cheaper than traditional CNC machining.

Download the blank mold insert design files—you’ll use them to create your injection mold design. The designs can also be easily scaled to accommodate most injection molders and mold frames. Alternatively, you can also design your own mold insert for the using the cavity diagrams of the master mold frames.

Your mold is now ready for printing. Export each half, making sure to check the “Selection Only” box in the Blender exporter.

Implementing these essential safety tips is a proactive way to safeguard your molding processes. For more guidance and support about custom injection molding, contact Sound View Plastics today and let us help you maintain a safe, efficient workplace.