Are you an APSX-PIM desktop injection molding machine owner eager to embark on the journey of custom mold design? Crafting your own molds unlocks a realm of possibilities, from rapid prototyping to small-scale production. However, mastering the custom mold design process requires meticulous planning and a keen understanding of your machine's capabilities. In this guide, we'll walk you through the major steps of custom mold design, tailored specifically for APSX-PIM users.Understanding the Basics of Custom Mold Design:Define Your Requirements: Start by clearly defining your project requirements. What are you molding? What are the desired dimensions, materials, and surface finishes? Understanding these aspects will guide your mold design process.Design Conceptualization: Design out your mold design concept, considering factors like parting lines, gating, and ejector pin placement. Utilize CAD software for precise modeling and visualization.Mold Material Selection: With APSX-PIM's air cooling feature in mind, opt for aluminum as your mold material. Its durability and efficient heat dissipation make it ideal for long-term use with the machine.Utilize Blank Mold Templates:&nbsp;Take advantage of the blank mold templates available on the APSX-PIM website. These templates provide a solid foundation for your mold design, saving time and ensuring compatibility with the machine.Tips and Tricks for APSX-PIM Users:Simplify Your Mold Design: Eliminate cosmetic features to streamline your mold design. By keeping it simple, you enhance manufacturability and reduce production costs. Remember, APSX-PIM excels in quick and cost-effective iterations compared to larger industrial machines.No Water Cooling Channels Needed: Since APSX-PIM features air cooling, there's no need for water cooling channels in your mold design. This simplifies the design process and eliminates the complexities associated with water cooling systems.Optimize for Rapid Iterations: APSX-PIM's compact size and quick setup allow for rapid iterations of mold designs. Take advantage of this by designing molds that facilitate fast iteration and testing of new product designs.Precision and Efficiency:&nbsp;APSX-PIM offers precise control over injection parameters. Design your molds with tight tolerances to ensure consistent part quality. Focus on optimizing cycle times and minimizing part warpage for efficient production runs.Conclusion:Custom mold design for APSX-PIM opens up a world of possibilities for desktop-scale injection molding. By understanding the major steps of the design process and leveraging tips and tricks tailored for APSX-PIM users, you can maximize the capabilities of your machine. Whether you're prototyping new products or producing small batches, mastering custom mold design will propel you towards success in the realm of injection molding.#injectionmolding #apsxpim #molddesign #CADCAM

Are you an APSX-PIM desktop injection molding machine owner eager to embark on the journey of custom mold design? Crafting your own molds unlocks a realm of possibilities, from rapid prototyping to small-scale production. 

Mastering Custom Mold Design for APSX-PIM: A Simple Guide

<h2 id="isPasted">Iconic PepsiCo Brand Finds Best Alternative to Expensive, Time-Consuming Conventional Metal Tooling</h2><a href="https://www.pepsico.com/" target="_blank">PepsiCo products</a> are enjoyed by consumers more than one billion times a day in more than 200 countries and territories around the world. PepsiCo generated more than $79 billion in net revenue in 2021, driven by a complementary beverage and convenient foods portfolio that includes Lay’s, Doritos, Cheetos, Gatorade, Pepsi-Cola, Mountain Dew, Quaker, and SodaStream. PepsiCo’s product portfolio includes a wide range of enjoyable foods and beverages, including many iconic brands that generate more than $1 billion each in estimated annual retail sales.<h2 id="isPasted">The challenge</h2><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyODE5MTU1MjQ1LWV6Z2lmLTEtNGZiZjE1OTIxMy5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib">Speed to market has never been more important in the consumer goods sector, as brand owners aim to develop new bottle and package designs to address ever-shifting customer desires. But creating conventional metal tooling for the blow molding of bottles is an expensive and time-consuming proposition. Once a CAD file of the package design is created, it can take up to four weeks to machine a metal tool, and then an additional two weeks to get a trial unit to do the actual blow molding. It also could easily cost up to $10,000 to produce a single metal tool set depending on its complexity, according to Max Rodriguez, senior manager of Global Packaging R&amp;D, Advanced Engineering and Design, at PepsiCo’s Valhalla research center.This has led many to try to apply 3D printing to shorten this process, but previous rapid tooling approaches also had their shortcomings. It would take two to three days to 3D print a single blow molding tool from Digital ABS (an expensive material) on a $250,000 PolyJet 3D printing machine. Even so, the resulting tool lacked durability and could produce only about 100 bottles before the mold began to fail. This prompted Rodriguez and his team to explore using a hybrid approach, combining parts of a conventional metal mold with 3D printed inserts.<blockquote id="isPasted">“Time and cost are obviously important, but more important is to have the ability to have the flexibility to run through a number of different design iterations at a record pace so that we can evaluate performance in all of the downstream activities. That really is what helps us accelerate packaging design and development.”Max Rodriguez, Senior Manager of Global Packaging R&amp;D, Advanced Engineering and Design, PepsiCo</blockquote><h3 id="isPasted">The application<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyODE5MjI2NDE3LVBlcHNpQ28tUGF0ZW50ZWQtM0QtUHJpbnRlZC1IeWJyaWQtTW9sZC5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"> </h3>Applying its patented technology and a hybrid approach, PepsiCo is using additive manufacturing as an enabler in various aspects of bottle development – accelerating and enhancing performance simulation, advanced system analysis and the production of high-quality, functional prototypes.<h3>The advantages</h3><ul><li>Compress prototype tooling development time from 4 weeks to 48 hours</li><li>Slash prototype tooling costs from $10,000 to $350 per mold set</li><li>Create durable tooling that can produce more than 10,000 bottles per mold</li><li>Enable multiple design iterations to allow for timely verification of downstream activities</li></ul><iframe width="640" height="360" src="https://www.youtube.com/embed/k7OiPJ9xfps?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe><h2 id="isPasted">More Than 10,000 Bottles at 96% Reduction in Cost</h2><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyODE5MjY2OTM4LVBlcHNpQ28tUGF0ZW50ZWQtTW9sZC0zRC1QcmludGVkLU5leGEzRC03Njh4NTg5LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">PepsiCo chose Nexa3D’s xPEEK147 from Henkel Loctite for the 3D printed tool inserts due to the material’s strength and impressive performance factors, including its very high heat-deflection temperature. While this hybrid approach is machine-agnostic, meaning it can use various types of 3D printers, PepsiCo has found the ultrafast, high-throughput <a href="https://nexa3d.com/3d-printers/nxe400/" target="_blank">Nexa3D NXE 400 3D printer</a> and accompanying material performance to be ideal for producing the mold components it needs.A complete mold set can be made in 12 hours, with 8 hours of 3D printing time and 4 hours of curing. These hybrid-made molds can then successfully be used for more than 10,000 bottles before failure – at up to a 96% reduction of cost compared to traditional metal tooling.

PepsiCo worked with Nexa3D’s partner Dynamism to validate the NXE 400 and the xPEEK147 material as ideal for their blow molding application requiring speed and durability.

CAD to Part in 48 Hours: PepsiCo Slashes Tooling Costs and Cycle Times with the help of NXE 400

Applications for <a href="https://www.protolabs.com/en-gb/services/3d-printing/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0424&utm_content=wevolver-comparing-3dp-and-im-cost-dt-0424" target="_blank">3D printing</a> are expanding rapidly in response to new materials, technologies and secondary processes announced seemingly daily. We now see additive manufacturing being used for not only prototyping, but also production parts to reduce assemblies and fabricate complex geometries.<a href="https://www.protolabs.com/en-gb/services/injection-moulding/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0424&utm_content=wevolver-comparing-3dp-and-im-cost-dt-0424" target="_blank">Injection moulding</a> continues as the workhorse that produces parts globally, without much fanfare. Perfected over decades, moulding remains the go-to service for cost-effective parts at quantities from 50 to over a million.A future where 3D printing replaces injection moulding may be far off, but today the two work beautifully in tandem. While 3D printing is often touted as a go-to service for prototyping, costs are typically prohibitive when scaling up to production volumes, which is where injection moulding can come in.Deciding which service is the right route for you? Let’s start with a look at cost drivers with both manufacturing services.Post processing workBuild time and post-processing are two main cost drivers. Determining ways to streamline your design or do without unnecessary finishes cuts down significantly on expenses.&nbsp;<img border="0" width="394" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyNjY5NjQ5NDc0LTE3MTI2Njk2NDk0NzQuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" alt="DMLS post processing" class="fr-fic fr-dii">3D Printing&nbsp;Build time: Far and away the most significant cost driver for 3D printing, a longer build time means a more expensive part. Take a solid cube, for example. While a simple part, printing the condensed cube layer by layer would take more time than if the cube’s interior used a cross-linked design, which requires less material and subsequently less machine time. Any necessary support structures during the printing process also increases machine time and cost.Material cost: Depending on the technology, 3D printing materials can add expense. While direct metal laser sintering (DMLS) recycles all unused powder, a process like selective laser sintering (SLS) uses a powder-based polymer process that does not allow for recycling, driving up cost.Post-processing: Required with nearly all 3D-printed parts, these processes strengthen parts, improve cosmetic appearance and more, but also require manual work that can be time consuming. Each 3D printing service also comes with necessary post-processing, so researching what is required on the front end will help determine cost. Injection MouldingPart complexity: Several design factors can lead to a more complex part with injection moulding. <a href="https://www.protolabs.com/en-gb/automated-design-analysis/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0424&utm_content=wevolver-comparing-3dp-and-im-cost-dt-0424" target="_blank">Design for manufacturability</a> (DFM) analysis is critical to identify modifications that reduce cost. For example, a small part doesn’t automatically translate to a smaller mould size. If your part design requires an undercut or side action, mould base size (and cost) increases significantly. If a cam or insert is required, your overall mould size can increase by £1,000-£2,000 per component. Design TimeFor engineers under increasing pressure to bring products to market, time is money. Quick iteration is key to shorten the timeline to perfect your design and move from concept to final part. That’s why we see our customers start with 3D printing during the prototyping process before moving to injection moulding once a part is ready for production volumes.Product iteration with 3D printing is faster and less expensive compared to injection moulding. If you identify a design flaw once a part is 3D printed, the CAD file can be easily tweaked and uploaded with another iteration printed and sent your way in days. Injection moulding requires significant expense with each design change due to the reworking of the mould. Furthermore, injection moulding usually requires more upfront design work since creating a mould can be a complex process with many factors to consider.<img border="0" width="461" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyNjY5NjQ5NDgzLTE3MTI2Njk2NDk0ODMuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" alt="Worker inspecting moulded part." class="fr-fic fr-dii">&nbsp;Set Up and ToolingSet up and tooling costs are another area where 3D printing is the clear winner, as it does not require investment in either. Injection moulding on the other hand comes with tooling costs and often a set-up fee with each run of moulded parts. As we discussed earlier, DFM analysis will help reduce tooling costs, but a mould may still bring thousands in up-front expense. Piece-Part PriceNow here’s an opportunity for injection moulding to shine. Piece-part price for injection moulding is going to be significantly lower compared to 3D printing once we reach a high volume of parts. While we have discussed the cost of tooling at length, each part that comes off that mould will be more cost-effective once you reach quantities that rationalise the initial investment.Fortunately, our applications engineers are well-versed in helping our customers determine if piece-part price cost savings justify the initial upfront costs of injection moulding.<img border="0" width="408" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyNjY5NjQ5NDkzLTE3MTI2Njk2NDk0OTMuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" alt="Black vapor smooth 3D printed parts." class="fr-fic fr-dii">Post-processingRegardless of technology, nearly all 3D-printed parts will require some level of post-processing. Mandatory processes after a part is printed include removing support structures or excess resin, depending on the technology you choose. The emergence of post-processing options, such as <a href="https://www.protolabs.com/en-gb/services/3d-printing/enhanced-surface-quality-for-sls-and-mjf-parts/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0424&utm_content=wevolver-comparing-3dp-and-im-cost-dt-0424" title="Enhanced Surface Quality for SLS and MJF parts" target="_blank">vapour smoothing</a>, improving strength and aesthetics have been critical in expanding the applications of additive manufacturing, but each comes with an additional expense.Injection moulding on the other hand comes with more than 100 thermoplastic and thermoset materials that eject from the mould with high-quality finishes fit for production. Finishing process are available to texture a mould, add threaded inserts, laser engraving and more, but aren’t necessary for the durability and finish of the part. Prototyping vs. On-Demand ManufacturingInjection moulding is still a viable option at the prototyping stage. When prototyping at Protolabs, we use a single-cavity aluminium mould that can produce hundreds of parts and can be typically delivered in a week or less. Our customers often choose prototyping with injection moulding if they need to complete design or material iterations, as well as assess cost or manufacturability trade-offs.Once past the prototyping stage, our customers often move to on-demand manufacturing, producing injection moulded parts at Protolabs speeds. Using a steel mould, part quantities are virtually unlimited. On-demand injection moulding with us allows you to meet inventory needs with no minimum order quantities, and offers supply chain flexibility through bridge tooling, just-in-time production, or dual-sourcing strategies. Subscribe for monthly design tips <a href="https://explore.protolabs.com/design-tips-registration/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0424&utm_content=wevolver-design-tip-subscribe-banner-0424" target="_blank" rel="noopener noreferrer">here.</a><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyNjY5Njc2NTYwLTE3MTI2Njk2NzY1NjAucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dib">

Explore key components such as build time, material cost, and part complexity, which can add or reduce cost to your part.

Comparing the Cost between Injection Moulding and 3D Printing

<a href="https://www.ifam.fraunhofer.de/en.html" target="_blank" id="isPasted">Fraunhofer IFAM</a> – an institute in the renowned Fraunhofer Society – is a recognized leader in the field of Metal Injection Molding (MIM), and is serving companies in the aerospace, energy, maritime and other demanding industries. To support research into new applications while lowering lead-times and costs, Fraunhofer recently decided to implement the Freeform Injection Molding (FIM) process powered by Nexa3D’s <a href="https://nexa3d.com/3d-printers/xip/" target="_blank">XiP Desktop 3D printer</a> and LSPc® technology. This platform enables manufacturers to quickly and cost-effectively prototype complex injection-molded parts before making investments in conventional metal tooling.<h2 id="isPasted">The challenge</h2><h3>Tooling for metal injection molding is costly and time-consuming to produce</h3><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzExMDE1MzUyNzcwLUZyYXVuaG9mZXItRklNLXRvb2wtMTgwMHgxMDEzLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"> In metal injection molding (MIM), metal powder is mixed with a plastic binder to create a feedstock that is then injected into a metal mold. The abrasive nature of the feedstock places high demand on the quality of the tooling, and the complexity of the MIM process typically results in the need for multiple iterations. Fraunhofer wanted to offer companies a path to quickly and cost-effectively test new concepts and turned to Nexa3D and Freeform Injection Molding to provide a solution.<blockquote id="isPasted">“Freeform Injection Molding provides us with the perfect tools to support innovative companies as they test out new concepts and materials.”– Sebastian Hein, Fraunhofer IFAM</blockquote><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzExMDE1Mzk5NjAzLTE3MTEwMTUzOTk2MDMucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dib"><h2 id="isPasted">The solution</h2><h3>3D printed injection mold tooling using xMOLD resin and Freeform Injection Molding</h3><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzExMDE1NDE0OTY3LUdFLUVuZ2luZS1CcmFja2V0LTE4MDB4MTIwMC5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"> Fraunhofer was inspired by other companies using <a href="https://nexa3d.com/digital-tooling/" target="_blank">Freeform Injection Molding</a> and decided to introduce the XiP desktop 3D Printer and the xMOLD resin. This compact platform is the ideal solution for printing molds in the product size range typically encountered in MIM, and the xMOLD tooling resin has a strong track record for the molding of high-performance materials.<h2 id="isPasted">The benefits</h2><h3>2-week design cycle enabled for complex metal parts</h3><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzExMDE1NDM4MDI1LUdFLU1ldGFsLUVuZ2luZS1CcmFja2V0LXYyLTE4MDB4MTIwMC5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"> By adopting the FIM process using Nexa3D’s XiP 3D printer and xMOLD material, the Fraunhofer IFAM team enables a host of benefits to their clients.Rapid Prototyping: FIM enables Fraunhofer to quickly prototype MIM parts for customer demonstration and validation testing. The material properties of FIM parts have been shown to closely match those produced with conventional steel tools, ensuring accurate performance evaluation.Time and Cost Savings: FIM allows Fraunhofer IFAM to dramatically reduce the time and cost required for pilot tooling production. The XiP printer’s exceptional speed allows for same-day printing and injecting while at the same time enabling cost and time savings exceeding 75% compared with conventional pilot tooling.De-risking Development and Innovation: Fraunhofer IFAM has already demonstrated that FIM is compatible with the gold-standard Catamold feedstocks from BASF, enabling customers to use well-characterized materials for their development and innovation.<h2 id="isPasted">Customer Impact</h2><h3>Prototype MIM for complex designs demonstrated</h3><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzExMDE1NDY5NDU4LUlNR18xNzk5LTc2OHg1MTIuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"> Metal injection molding has suffered from a scarcity of prototyping options. Conventional AM-based approaches, whether powder – or binder-based, cannot be used to evaluate flow paths, in-mold stress patterns or warpage of molded parts during debinding and sintering. As a consequence, injection molders have had to invest in high-cost pilot tools when wanting to validate part designs and process parameters. Already with the first project – modeled around the GE Jet Engine Bracket – Fraunhofer IFAM demonstrated the simplicity, speed and design freedom unlocked with Freeform Injection Molding.The Fraunhofer team decided on a bracket design that would be suited for injection molding, and to use a well-known off-the-shelf Catamold 17-4PH feedstock from BASF as the material. A XiP printer cell was used to print the soluble injection mold tooling, and an Arburg 320 injection molding machine was employed to complete the molding.The project confirmed several important aspects of Freeform Injection Molding:<ul><li>Mold design time shrinks from days to hours, as molds do not have to incorporate split lines, ejector pins or sliding features.</li><li>The manufacturing of test molds can be done in days instead of weeks.</li><li>Injection Molding can be carried out using standard injection molding machines and feedstocks, and delivering a material quality that rivals that of conventional metal injection molding.</li></ul>To learn more about Freeform Injection Molding, download the&nbsp;<a href="https://nexa3d.com/case-studies/fraunhofer-case-study/#3d-printed-tooling" target="_blank">3D Printed Tooling Design Guide</a> or&nbsp;<a href="https://nexa3d.com/contact/" target="_blank">reach out</a> for more information.

Research institute adopts Freeform Injection Molding to provide rapid prototyping of complex metal parts

Fraunhofer Speeds Up Metal Injection Molding with 3D-Printed Tooling

At A GlanceChallengeInjection moulding 210 parts in 5 weeks for the battery pack cooling system for a fully electric super sports car prototypeSolutionHutchinson relied on Protolabs to obtain three different components within the required time and with the prescribed quality. The speed of interaction between Hutchinson and Protolabs, combined with experience in the automotive sector, allowed for the production of 210 parts in less than 5 weeks from the first contact.OutcomeThe iteration speed of Protolabs and Hutchinson led to perfect parts being delivered on time, ready to be tested and installed on the supercar prototype, reducing validation and testing times.<hr> In June 2023, 138,937 new cars were registered in Italy. Of these, just under 10% were electric cars: 7,539 plug-in hybrids and 6,159 fully electric vehicles. Adding the remarkable figure of 48,937 new electric hybrids, electric and hybrid cars together accounted for almost 45% of new registrations. &nbsp; <a href="https://www.hutchinson.com/en" target="_blank">Hutchinson</a>, a Total Group subsidiary, is a French multinational with 38,000 employees across more than 100 industrial sites in 25 countries, specialising in designing and manufacturing polymer-based products and systems for fluid management. Located in Rivoli, near Turin, is the global centre of competence for automotive fuel systems, typically for diesel or gasoline vehicles. However, in electric cars, such a system is non-existent. Instead, a similarly crucial component for the proper functioning of electric cars is the battery pack temperature stabilisation system, a critical node for vehicle safety. &nbsp; In 2025, Italy will introduce a fully electric supercar, and work on prototype development has already begun, thanks to the collaboration between <a href="https://www.protolabs.com/en-gb/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-automotive-0124&utm_content=wevolver-hutchinson-cs-0324" target="_blank" rel="noopener noreferrer">Protolabs</a> and Hutchinson.Designing a supercar means thinking big, and Engineer Valter Mondini, Project Manager, understands that no detail can be left to chance in a project of such significance. Hutchinson was brought in to find the best solution for cooling the battery pack. For a car to be defined as a supercar, it must deliver exceptional performance in speed and range, the latter being determined by a battery pack as extensive as possible while minimising space for other elements.The main technological challenge was minimising the space the hydraulic system used to cool the battery pack took. This involved replacing the&nbsp;<a href="https://www.protolabs.com/en-gb/materials/?utm_source=eureka&utm_medium=referral&utm_campaign=uk-automotive-0124&utm_content=eureka-spotlight-hutchinson-cs-0124" target="_blank" title="Materials">material</a> used to make the tubes. Initially, the tubes were made of rubber that contained water and glycol, but Protolabs replaced the material with extruded plastic, ensuring the same mechanical performance. Each piece had to be flawless to guarantee a seal of up to 4 Bar. It was crucial to avoid any moulding imperfections, such as burrs, as they could mark the tube during the cold fitting phase and compromise the hydraulic system's seal.<img border="0" width="359" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwOTM3MTk2MTMyLTE3MTA5MzcxOTYxMzIuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" alt="Protolabs and Hutchinson collaborate on the first Italian electric supercar" class="fr-fic fr-dii" style="width: 451px;">"Protolabs is among Hutchinson's accredited suppliers and collaborates on projects where the speed of iteration and the quality of the products obtained are unparalleled. They accepted the challenge. The timelines were extremely tight: we needed to produce four different&nbsp;<a href="https://www.protolabs.com/en-gb/services/injection-moulding/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-automotive-0124&utm_content=wevolver-hutchinson-cs-0324" target="_blank" title="Injection Moulding" rel="noopener noreferrer">injection-moulded</a> components in the specified material, with particularly tight tolerances given the importance of the battery cooling hydraulic system. Given the project's significance," explains Engineer Mondini of Hutchinson, we could not afford any mistakes.<blockquote>"Protolabs is among Hutchinson's accredited suppliers and collaborates on projects where the speed of iteration and the quality of the products obtained are unparalleled. They accepted the challenge." V. Mondini, Project Manager &amp; Engineer at Hutchinson</blockquote>&nbsp;"Upon receiving the initial request from Hutchinson," explains Stefano Mosca, Senior Account Manager at Protolabs in Italy, "we immediately involved our injection moulding centre of excellence in Eschenlohe, which is particularly accustomed to responding to requests from the automotive sector. We were already familiar with the sector's required standards and knew that when we are involved in a project, it is primarily for the speed and quality assurance of the parts we produce. In 5 weeks, we validated the project, produced the moulds, chose the filler percentage of both Nylon and PPS together with the customer, injected moulded the parts, and shipped them."The project is a fine example of international collaboration. The development project for these components was undertaken in Italy, developed in France, produced in Germany, tested in Italy, and a portion of the parts was shipped from Protolabs to Poland to be mounted on some prototypes— a fitting example of how an international supercar, which will be sold worldwide, is born.<img border="0" width="295" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwOTM3MTk2MTM5LTE3MTA5MzcxOTYxMzkuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" alt="A close-up of several pipesDescription automatically generated" class="fr-fic fr-dii" style="width: 370px;">&nbsp;&nbsp;About Hutchinson:Hutchinson designs and manufactures smart solutions for a world on the move and contributes to future mobility on land, in the air and at sea. With expertise in fluid transfer, sealing, anti-vibration systems and materials &amp; structures, Hutchinson is a global leader in&nbsp;developing innovative solutions for sustainable mobility.To find out more, visit the&nbsp;<a href="https://www.hutchinson.com/en/accueil" target="_blank">Hutchinson</a> website.

Designing components for a super car means thinking big, delivering exceptional performance, and executing a flawless design.  Learn how Hutchinson worked with Protolabs to injection mould a battery pack cooling system in just 5 weeks.



Protolabs and Hutchinson collaborate on the first Italian electric supercar

SPT Vilecon is a fully integrated provider of development and manufacturing services to the medical device industry, working at the intersection of design, development, and manufacturing to allow customers to move a new product from concept to commercialization, and with inhouse tool building in place to ensure shortest possible lead-times. Certified according to ISO 13485, the European standard governing medical device manufacturing, they provide product development support as well as injection molding and other manufacturing services to a large number of companies in northern Europe.Recognizing that speed is always of the essence, SPT decided to implement Nexa3D Freeform Injection Molding. The goal was to help customers shorten times-to-market on complex medical devices in demanding medical-grade materials and to expand on the range of materials that can be quickly and reliably used in prototyping and early device test manufacturing.<h2 id="isPasted">The challenge</h2><h3>Medical device development requires production-grade prototypes</h3><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwMTI5MTgzNDEyLW1lZGljYWwtZGV2aWNlLXByb2R1Y3Rpb24tZ3JhZGUtcHJvdG90eXBpbmctMTgwMHgxMzM5LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"> Medical device manufacturers face rigorous regulatory requirements when introducing new devices into the market. A medical device needs to be safe and efficient to use for the intended purpose, and it is the job of the manufacturer to demonstrate that a given device meets these essential requirements. To do so, manufacturers must develop elaborate test protocols that evaluate every aspect of device manufacturing and usage, and they must ensure that tests are carried out in a way that accurately represents the conditions that apply for the manufacturing and usage of the finished medical device. The later these tests are carried out, the more severe the consequences are if a test fails. Medical device companies are constantly on the lookout for tools and methods that help them improve early-stage device testing to reduce development risks and costs of rework.SPT Vilecon often works with Silicones, a group of materials that are heavily used in the medical device industry due to their excellent chemical resistance, mechanical performance and biocompatibility. However, silicone parts are notoriously difficult to prototype and test, since most grades need to be injection-molded to achieve their full performance.<blockquote id="isPasted">“Freeform Injection Molding has enabled us to dramatically accelerate the delivery of production-grade prototypes and low-volume productions in challenging materials and designs.”– Bjarne Andersen, CEO, STP Vilecon</blockquote><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwMTI5Mjk4NTI5LTE3MTAxMjkyOTg1MjkucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dib"><h2 id="isPasted">The solution</h2><h3>3D printed injection mold tooling allows early verification, new applications</h3><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwMTI5MzQwMDQzLXhpcC1kZXNrb3AtM2QtcHJpbnRlci1maW0tbWVkaWNhbC0xODAweDE2NTUuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"> To meet customer demands for rapid prototyping of silicones, and other complex medical-grade materials, SPT Vilecon wanted a prototyping platform that would integrate seamlessly with their existing tool-building and injection molding capabilities. Other key requirements included biocompatibility, compatibility with the wide range of thermoplastics and silicones already in use, as well as design freedom for complex part prototyping. In the end, they decided to implement Nexa3D’s XiP desktop system and Freeform Injection Molding with xMOLD resin. This compact and highly versatile platform was the only alternative that met all the key requirements, while at the same time enabling SPT Vilecon to expand into new domains based on metal and ceramic injection molding.<h2 id="isPasted">The benefits</h2><h3>2-day development and verification of complex silicone parts</h3><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwMTI5MzU1MjczLXNwdC12aWxlY29uLTNkLXByaW50ZWQtdG9vbHMtMTgwMHgxMjAwLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"> With Freeform Injection Molding, SPT Vilecon was able to offer a customer developing an intravenous silicone product, early design and material verification by utilization of 3D printed tools.Early Verification: The use of 3D-printed xMOLD tooling enabled the customer to obtain injection-molded silicone parts in a medical-grade silicone within two days, and to verify key design and performance aspects.Rapid iterations: At the same time, important design input was collected from the first tests, which could be integrated in a second iteration that took only a couple of hours to complete. In comparison, the conventional metal tooling that would normally be needed for this kind of verification would have taken more than six weeks to design and procure, and the adjustments needed for the second iteration would have taken the inhouse tool-shop a week to complete.Cost and time savings: The costs of the 3D-printed silicone molds for the first and second iterations were less than EUR 2.000 combined. And the two-day design cycle was more than 90% faster than the speed achievable with conventional metal tooling.Seamless scalability: Based on the design input collected from the first two iterations, the design of the silicone part was approved and the manufacturing of a metal tool could be initiated with full confidence of part moldability and performance. The collected design input and learnings enabled the inhouse tool-shop to produce the metal tooling within 4 weeks, with no iterations needed in the final tool.<h2 id="isPasted">Customer Impact</h2><h3>Compliance with project timeline, budget ensured through early verification</h3><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwMTI5Mzc3Mzk2LW1lZGljYWwtZGV2aWNlLW1hbnVmYWN0dXJlZC0zZC1wcmludGVkLTEyMDB4MTgwMC5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"> Medical device manufacturers face strong pressures to bring new and innovative products to market. Robust and valid prototyping and verification is key to minimize costs, time and risks associated with the development. By implementing Freeform Injection Molding, SPT Vilecon has created a new toolbox for medical device companies seeking to accelerate their innovation and obtain early verification of part performance and moldability.Using the XiP with Freeform Injection Molding, a medical device manufacturer was able to save 6 weeks, and 87% of prototyping investments, while at the same time removing a challenging silicone component from the critical path of product development.SPT Vilecon has been able to start expanding the range of injection mold prototyping into the domains of silicone, metal and ceramic injection molding, to provide medical device manufacturers with an even wider selection of product development and verification services.

Medical device manufacturer adopts Nexa3D’s FIM process to shorten times-to-market on complex medical devices

SPT Vilecon Accelerates Medical Device Development with Freeform Injection Molding

Is the 3D printing not enough for your prototyping applications for functional testing? Are your iterations for the traditional injection mold making too costly and time consuming for a new part you are developing? You are also not 100% sure if this part design is your final design. With Freeform Injection Molding (FIM), you can cut the cost and time significantly and make multiple iterations until you find your sweet spot. Then you can make the metal mold as your final step before the production with 100% confidence.&nbsp; The APSX-PIM desktop injection molding machine can speed up the process with reduced costs and faster turnarounds. Simply design the mold, 3D print it, inject the plastic in it then demold or directly use the part.&nbsp; First off, what exactly is Freeform Injection Molding? With FIM, complex geometries can be achieved without the constraints of traditional tooling, thanks to the high-speed, high-resolution capabilities of Nexa3D printers. You can even dissolve the mold made by xMOLD material to test the plastic part functionality until it is perfect. Nexa3D utilizes its groundbreaking LSPc (Lubricant Sublayer Photo-curing) technology, enabling blazing fast print speeds without compromising on detail.&nbsp; But what if you need larger quantities of your parts? That's where the APSX-PIM desktop injection molding machine comes in. This compact yet powerful machine allows you to quickly and affordably produce small to medium-sized batches of parts using traditional injection molding techniques. By combining the precision 3D printing with the scalability of injection molding, you have a winning combination for accelerating your product development process. Not only does this save time, but it also significantly reduces costs compared to traditional manufacturing methods. Whether you're a startup looking to iterate quickly on your designs or an established company aiming to streamline your production line, Freeform Injection Molding with Nexa3D and the APSX-PIM machine offers unparalleled flexibility and efficiency. Freeform Injection Molding is changing the game, and with Nexa3D and APSX-PIM, you're well-equipped to stay ahead of the curve. Please visit the <a target="_self" href="http://www.apsx.com/" data-test-app-aware-link="">www.apsx.com</a> website to get more details.&nbsp; <iframe width="640" height="360" src="https://www.youtube.com/embed/3fdu_OptGN4?&amp;wmode=opaque&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe> <a href="https://youtu.be/3fdu_OptGN4?si=z1-sMfi1PvNg3u6b" target="_blank" rel="noopener noreferrer">YOUTUBE VIDEO.</a><a href="https://www.linkedin.com/feed/hashtag/?keywords=injectionmolding&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7168001489381117953" data-test-app-aware-link="" target="_blank">#injectionmolding</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=prototyping&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7168001489381117953" data-test-app-aware-link="" target="_blank">#prototyping</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=manufacturing&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7168001489381117953" data-test-app-aware-link="" target="_blank">#manufacturing</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=engineering&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7168001489381117953" data-test-app-aware-link="" target="_blank">#engineering</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=apsxpim&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7168001489381117953" data-test-app-aware-link="" target="_blank">#apsxpim</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=nexa3d&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7168001489381117953" data-test-app-aware-link="" target="_blank">#nexa3D</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=xmold&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7168001489381117953" data-test-app-aware-link="" target="_blank">#xMOLD</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=plasticparts&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7168001489381117953" data-test-app-aware-link="" target="_blank">#plasticparts</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=partdesign&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7168001489381117953" data-test-app-aware-link="" target="_blank">#partdesign</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=moldingmachine&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7168001489381117953" data-test-app-aware-link="" target="_blank">#moldingmachine</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=3dprinting&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7168001489381117953" data-test-app-aware-link="" target="_blank">#3dprinting</a>

Are your iterations for the traditional injection mold making too costly and time consuming for a new part you are developing? You are also not 100% sure if this part design is your final design. 

Is the 3D printing not enough for your prototyping applications for functional testing?

Makers and innovators wanted! Welcome to the world of injection molding, cnc machining and Swiss lathe using the APSX Machines. We'll be showcasing the APSX-NANO for creating ejector pins and a reamer tool, the Spyder CNC for machining the mold and reaming ejector pin holes, and finally, the APSX-PIM for producing plastic parts using the mold we create. It's the perfect success trio! Let's kick things off with the APSX-NANO, a compact and versatile machine that's perfect for creating precision components. Today, we'll be using it to craft ejector pins and a reamer tool for our injection mold. With its user-friendly interface, the APSX-NANO allows us to easily manufacture our ejector pins. These pins play a crucial role in the injection molding process, ensuring smooth ejection of the finished parts from the mold. And don't forget the reamer tool! The APSX-NANO makes the custom designed reamer tool as well. Now that we have our ejector pins and reamer tool, it's time to move on to the Spyder CNC for machining the mold itself. The SPYDER CNC ensures accurate and clean holes in our mold for the ejector pins. This small but powerful CNC machine allows us to take our design from the digital realm to the physical world with accuracy. With the Spyder CNC, we can carve out our mold design with incredible detail. The machine's robust capabilities ensure a smooth and precise finish, providing the foundation for a high-quality injection mold. Now that our mold is ready, it's time for the grand finale - producing plastic parts using the APSX-PIM, the heart of our success trio! The APSX-PIM is an injection molding machine that brings our creations to life. By injecting molten plastic into the mold we've crafted, we can replicate our design with ease and efficiency. And there you have it, the Success Trio in action! From crafting ejector pins and reamer tools with the APSX-NANO, precision machining the mold with the Spyder CNC, to bringing our ideas to life with the APSX-PIM – it's a seamless process that opens up endless possibilities for creators like you.<a href="https://youtu.be/fF-tIKxt43s?si=f3w2Y6bHR-2B9Eda" target="_blank" rel="noopener noreferrer">YOUTUBE VIDEO</a>.More details: <a href="https://www.apsx.com/" data-attribute-index="0" target="_self">https://www.apsx.com/</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=apsxllc&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7163648087201181696" data-attribute-index="1" target="_blank">#apsxllc</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=apsxnano&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7163648087201181696" data-attribute-index="2" target="_blank">#apsxnano</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=swisscnc&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7163648087201181696" data-attribute-index="3" target="_blank">#swisscnc</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=spydercnc&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7163648087201181696" data-attribute-index="4" target="_blank">#spydercnc</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=apsxpim&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7163648087201181696" data-attribute-index="5" target="_blank">#apsxpim</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=cncmachining&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7163648087201181696" data-attribute-index="6" target="_blank">#cncmachining</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=injectionmolding&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7163648087201181696" data-attribute-index="7" target="_blank">#injectionmolding</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=molddesign&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7163648087201181696" data-attribute-index="8" target="_blank">#molddesign</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=moldmaking&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7163648087201181696" data-attribute-index="9" target="_blank">#moldmaking</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=rapidprototyping&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7163648087201181696" data-attribute-index="10" target="_blank">#rapidprototyping</a>

Are you a manufacturer looking to streamline your production process while saving costs?

Desktop Machines for Injection Mold Making

Traditionally, this process has been reserved for large-scale production in industrial settings. However, with the development of desktop injection molding machines, global companies, small businesses and hobbyists can now take advantage of this technology to speed up their product development and small batch production.&nbsp; Cost-Effective One of the main benefits of desktop injection molding machines is their cost-effectiveness. Traditional injection molding machines can cost hundreds of thousands of dollars, making them inaccessible for small businesses and individuals.&nbsp; Compact and Portable Another advantage of desktop injection molding machines is their compact size and portability. Traditional injection molding machines are large and require a dedicated space in an industrial setting. Desktop machines, on the other hand, are much smaller and can easily fit on a desk or workbench.&nbsp; Easy to Use Desktop injection molding machines are designed to be user-friendly and easy to operate. They come with intuitive controls and can be set up and ready to use in a matter of minutes. This makes them accessible to individuals with little to no experience in plastic manufacturing.&nbsp; Versatile Desktop injection molding machines are also highly versatile. They can be used to produce a wide range of plastic parts, from small and intricate pieces to larger and more complex ones. This versatility makes them suitable for a variety of industries, including automotive, medical, and consumer goods.&nbsp; High-Quality Results Despite their smaller size and lower cost, desktop injection molding machines are capable of producing high-quality plastic parts. They use the same technology and materials as traditional machines, ensuring precision and accuracy in the production process. This means that businesses and individuals can produce professional-grade plastic parts without the need for expensive equipment. In conclusion, desktop injection molding machines offer a range of benefits that make them a game-changer in the plastic manufacturing industry. From cost-effectiveness and compact size to versatility and high-quality results, these machines are revolutionizing the way plastic parts are produced. As technology continues to advance, we can expect to see even more advancements in desktop injection molding machines, making them an essential tool for businesses and individuals alike. Visit <a target="_self" href="http://www.apsx.com/" data-test-app-aware-link="">www.apsx.com</a> for more information about the APSX Machines by&nbsp;<a target="_self" href="https://www.linkedin.com/company/apsx-llc./" data-test-app-aware-link="">APSX, LLC.</a>.&nbsp; <a href="https://www.linkedin.com/feed/hashtag/?keywords=injectionmolding&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7170461148239126529" data-test-app-aware-link="" target="_blank">#injectionmolding</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=rapidprototyping&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7170461148239126529" data-test-app-aware-link="" target="_blank">#rapidprototyping</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=rapidtooling&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7170461148239126529" data-test-app-aware-link="" target="_blank">#rapidtooling</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=apsxllc&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7170461148239126529" data-test-app-aware-link="" target="_blank">#apsxllc</a><a href="https://youtu.be/SZ35BVJ-yvE?si=Vc1URbHcgTbsHHgs" target="_blank" rel="noopener noreferrer">APSX-PIM Short Video</a>

In the world of plastic manufacturing, injection molding is a widely used process for creating high-quality, precise plastic parts. 

Why would you need a desktop injection molding machine?

<a href="https://xometry.eu/en/injection-moulding/" target="_blank">Injection moulding</a> is a plastics manufacturing technology that is capable of very high production volumes. The process works by injecting liquid plastic into a mould at very high pressure. <a href="https://xometry.eu/en/compression-moulding/" target="_blank">Compression moulding</a>, on the other hand, is better suited to medium-volume production and is typically used with rubbers and silicones.Injection moulding is better suited to creating complex parts, whereas compression moulding is better suited to simple geometries and large panels. Injection moulding is highly automated and does not need constant human supervision, while compression moulding often requires human intervention to load a charge and remove completed products. Tooling is also cheaper for compression moulding.&nbsp;<h2>Injection moulding definition and comparison to compression moulding</h2>Injection moulding works by injecting molten thermoplastic into a mould cavity. During the <a href="https://xometry.eu/en/injection-moulding-technology-overview/" target="_blank">plastic injection process</a>, the plastic resin pellets are melting inside a barrel. The barrel contains a screw with a shaft whose diameter increases along its length. As the screw rotates, plastic is forced into an incrementally smaller volume. This compression is the primary mechanism responsible for melting the plastic. The barrel is also heated to supply additional heat. Once enough plastic to fill the mould has melted, the screw retracts and then is pushed forward to force the plastic resins into the mould at very high pressures.&nbsp;Moulds are made from at least two components and are held together with hydraulic rams so that the high-pressure plastic injected into the mould cannot escape from the parting line. The mould has cooling channels that cool the part enough so that it can be ejected from the mould without damaging it. Injection moulding can achieve high production volumes unmatched by any other plastic processing technique. Compression moulding, on the other hand, is better suited to medium-volume production.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709637518953-ezgif-7-34a4753f4f.gif" style="width: 100%px;" class="fr-fic fr-dib">Injection moulding process animation<h3 id="isPasted">Advantages of injection moulding compared to compression moulding</h3>Listed below are some advantages and disadvantages of injection moulding compared with compression moulding:<ul><li>Injection moulding is a method for large production runs that can produce millions of parts per machine annually.&nbsp;</li><li>Due to the high levels of automation and rapid manufacturing speed, injection moulded parts are cheaper than compression moulded parts.</li></ul><h3>Disadvantages of injection moulding compared to compression moulding</h3>Listed below are some disadvantages of injection moulding compared with compression moulding:<ul><li>Injection moulding requires very high plastic injection pressures. The mould must therefore be built to withstand these high pressures. This adds cost to the tooling.&nbsp;</li><li>Injection moulding is not well suited to manufacture large, thin parts like vehicle panels.</li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709637547696-injection-moulding-setup-768x588.jpg" style="width: 100%px;" class="fr-fic fr-dib">Injection moulding setup<h2 id="isPasted">Compression moulding definition and comparison to injection moulding</h2>Compression moulding is a process most often used to manufacture parts from pliable materials. <a href="https://xometry.eu/en/compression-moulding-technology-overview/" target="_blank">This moulding technique</a> typically employs a two-part mould, with one part fixed to the base of the compression moulding tool while the top half is free to move up and down. The moulds are usually heated to help cure the final product while also heating the charge before compression. A precisely weighed-out charge is heated until it is pliable. It is then placed into the bottom half of the mould.&nbsp;The top half then moves down and forces the charge to conform to the desired shape of the mould. The heated mould stays closed while the material is allowed to cure. This typically takes a few minutes. Once cured, the part is removed from the mould. Post-processing is required to cut off any flash. Flash (or excess material at the parting line of the mould) is a common occurrence for compression-moulded parts.Compression moulding is used for creating reinforced panels. The process involves laying out fibre-filled plastic sheets in the bottom half of the mould. Thereafter, the top half of the mould compresses and heats the material to force the plastic throughout the mould, creating a composite part. This is how large plastic car bumpers are made.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709637616083-ezgif-7-1b2e488406.gif" style="width: 100%px;" class="fr-fic fr-dib">Compression moulding process animation<h3 id="isPasted">Advantages of compression moulding compared to injection moulding?</h3>Listed below are some advantages of compression moulding compared to injection moulding:<ul><li>Compression moulding can make use of SMC (Sheet Moulding Compound) and BMC (Bulk Moulding Compound) to create composite panels. These panels do not have continuous fibre-impregnated sheets, but rather chopped fibre strands that are distributed throughout the bulk material. The injection moulding method cannot make composite material parts.&nbsp;</li><li>Compression moulds do not need to withstand high internal pressures as do injection moulds. Instead, the only load they experience is a compression force from above. This means that compression moulds tend to be less expensive.</li></ul><h3>Disadvantages of compression moulding compared to injection moulding</h3>Listed below are some disadvantages of compression moulding compared to injection moulding:<ul><li>Compression moulding is a very manual and slow process. Even if a robot arm is used to add the charge and remove the product, the cycle time between parts is still much slower than injection moulding due to the need for the parts to be set before being removed.</li><li>Compression moulding cannot create plastic parts with high levels of complexity. The materials used are typically very viscous and as a result, they don’t flow well into small, complicated features.</li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709637640110-rubber-compression-machine-768x512.jpg" style="width: 100%px;" class="fr-fic fr-dib">A rubber compression machine<h2 id="isPasted">Comparison table between injection moulding and compression moulding</h2>Attributes of compression moulding and injection moulding are shown in the table below:<figure><table><tbody><tr><td>Attribute</td><td>Injection Moulding</td><td>Compression Moulding</td></tr><tr><td>High-volume production process</td><td>Yes</td><td>No</td></tr><tr><td>Materials</td><td>Thermosets, thermoplastics (including fibre and metal-filled), thermoplastic elastomers, metal-filled polymers, fibre-filled thermoplastics</td><td>Thermosets, thermoplastics, silicone, unvulcanized rubber, BMC, SMC</td></tr><tr><td>High tooling cost</td><td>Yes</td><td>No</td></tr><tr><td>Can produce large, thin-walled panels</td><td>No</td><td>Yes</td></tr><tr><td>Post-processing required</td><td>Yes</td><td>Yes</td></tr></tbody></table></figure> Injection moulding is better suited to high-volume production whereas compression moulding is better suited to pliable and flexible materials. Compression moulding also has cheaper tooling costs.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709637659491-capabilities-injectionmolding-xometry-768x511.webp" style="width: 100%px;" class="fr-fic fr-dib">Blue injection moulded bottle nozzles in high-volume<h3 id="isPasted">Injection moulding vs. compression moulding: Lead cost comparison</h3>When it comes to individual part cost, injection moulding can produce inexpensive, complex parts. However, this manufacturing process is only cost-competitive if production run volumes are large enough to spread the high cost of injection moulding tooling over a sufficient number of pieces. At lower volumes, compression moulding is cheaper than injection moulding due to the lower initial mould costs.<h3>Injection moulding vs. compression moulding: Speed comparison</h3>Injection moulding is significantly faster than compression moulding. The cycle time for injection moulded parts can be a few seconds, whereas compression moulding cycle times can easily reach a few minutes. This is because compression moulded components often need to cure thanks to the heating process before they are removed from the mould.<h3>Injection moulding vs. compression moulding: Volume comparison</h3>Injection moulding is a high-volume production method that is unmatched by any other manufacturing technology. Injection moulding processes can be fully automated, while compression moulding often requires a person to place the raw materials into the mould, remove it, and post-process it.<h3>Injection moulding vs. compression moulding: Materials comparison</h3>Injection moulding can make use of&nbsp;<a href="https://xometry.eu/en/injection-moulding-materials-selection-guide/" target="_blank">rigid thermoplastics as well as thermoplastic elastomers</a>. Compression moulding more often makes use of flexible elastomers like rubber and silicone, but can also produce rigid composite components by making use of SMC and BMC.<h2>Summary</h2>This article presented the comparison of injection moulding to compression moulding, explained what they are, and discussed the different attributes of each.Xometry provides a&nbsp;<a href="https://xometry.eu/en/capabilities/" target="_blank">wide range of manufacturing capabilities</a>, including&nbsp;<a href="https://xometry.eu/en/injection-moulding/" target="_blank">plastic injection moulding</a>,&nbsp;<a href="https://xometry.eu/en/compression-moulding/" target="_blank">compression moulding</a> and other value-added services for all of your prototyping and production needs.

This article will describe the similarities and differences between injection moulding and compression moulding to help you determine which process is best for your project in terms of the manufacturing process, materials used, and production rates.

Injection Moulding vs. Compression Moulding: Differences and Comparison

<div data-id="9908f31" data-element_type="widget" data-widget_type="heading.default" id="isPasted"><h2>A global automotive supplier</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709524209040-ti_fluid_systems_IMG_0032.jpg.webp" style="width: 100%px;" class="fr-fic fr-dib">TI Fluid Systems is one of the biggest suppliers for automotive fluid solutions. Source: TI Fluid Systems</div><div data-id="69b735e" data-element_type="widget" data-widget_type="text-editor.default"><a href="https://tifluidsystems.com/" target="_blank">TI Fluid Systems</a> is a manufacturer for automotive fluid technology headquartered in Oxford, England. With more than 100 years of experience and 28’000 employees across 29 countries, the company has established itself as a major supplier to the automotive industry. Primarily, TI Fluid Systems specializes in the development and production of industry-leading fluid carrying systems, as well as fuel tank and delivery systems that are found in two-thirds of all vehicles worldwide.<div data-id="371df47" data-element_type="widget" data-widget_type="heading.default" id="isPasted"><h2>Innovation from Poland</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709524232497-IMG_8402.jpg.webp" style="width: 100%px;" class="fr-fic fr-dib">Under the lead of Paweł Pułtorak, the Sintratec S2 has been in regular use for over two years at TI Fluid Systems.</div><div data-id="a4a60e8" data-element_type="widget" data-widget_type="text-editor.default">One of TI Fluid Systems 114 branches is located in Bielsko-Biała, Poland, where Paweł Pułtorak has been the head of the design department for the last 18 years. Under his guidance, the team has gradually incorporated additive technologies into their research and development. «3D printing is a very important tool for supporting the work of engineers in the design department», states Pułtorak. With these advanced manufacturing methods, the team is able to reduce production costs and time-to-market.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709524259047-1709524259047.png" class="fr-fic fr-dib">The design department uses selective laser sintering to rapidly advance their product development.<div data-id="66f7fc8" data-element_type="widget" data-widget_type="heading.default" id="isPasted"><h2>SLS for precise prototypes</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709524288377-cleaningpart_TIFLUID_3-1.jpg.webp" style="width: 100%px;" class="fr-fic fr-dib">SLS parts being depowdered inside the Sintratec Material Handling Station.&nbsp;</div><div data-id="bc27b16" data-element_type="widget" data-widget_type="text-editor.default">«The main use of the 3D prints is to verify the shape and geometry of the designed elements before making the injection mold and going into series production», Pułtorak explains. Due to the high requirements for prototypes in the automotive sector, the company decided to invest in a <a href="https://sintratec.com/sls-3d-printer/amp/sintratec-s2/" target="_blank">Sintratec S2</a> – a selective laser sintering (SLS) system. «Other technologies did not allow us to print as precise components as SLS does», says Pułtorak. With the robust <a href="https://sintratec.com/3d-printing-materials/sintratec-pa12-powder/" target="_blank">Sintratec PA12</a> material in particular, the engineers can cover the majority of the company’s prototyping needs.<div data-id="af667bd" data-element_type="widget" data-widget_type="heading.default" id="isPasted"><h2>A wide range of applications</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709524305009-compositesls_web.jpg.webp" style="width: 100%px;" class="fr-fic fr-dib">3D printed with PA12 nylon: Automotive components similar to these are laser sintered by TI Fluid Systems.</div><div data-id="5c13cdf" data-element_type="widget" data-widget_type="text-editor.default">According to Paweł Pułtorak, the Sintratec S2 is used practically every day. «The SLS parts allow us to assess whether there are collisions in our assemblies», explains the department head. «We also use them during our project group meetings and in functional tests.» Apart from the previously mentioned prototypes, the main pieces printed at TI Fluid Systems are housings, construction and tooling elements, jaws and work pieces to assist with assembly, as well as spare parts for the maintenance department.<div data-id="738f8b9" data-element_type="widget" data-widget_type="heading.default" id="isPasted"><h2>Accuracy and strength combined</h2></div><div data-id="8731b84" data-element_type="widget" data-widget_type="text-editor.default">«What we like the most about the Sintratec S2 system is the accuracy of 3D printed elements», emphasizes Pułtorak. For the TI Fluid Systems design department, the precision and strength of these components plays a crucial role in their development efforts. After over two years in use, the economic benefits of the Sintratec S2 have become apparent as well. «The machine is definitely a good investment», summarizes Paweł Pułtorak.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709524343019-1709524343019.png" class="fr-fic fr-dib"></div></div></div></div></div>

At a Polish branch of TI Fluid Systems, functional prototypes and spare parts for the automotive industry are selectively laser sintered. Using a Sintratec S2, Paweł Pułtorak’s team prints precise and complex parts to validate their designs.

Shifting into high gear with SLS

Aitiip is a leading Spanish research and development institute, and serves companies in the aeronautics, automation, industrial and packaging sectors. The institute possesses strong platforms for the characterization of materials and processes and is known as a powerful integrator of technologies, which is constantly on the look-out for the next transformative technology. A year ago, Aitiip implemented an NXE 400 printer platform from Nexa3D, to explore integrations of additive manufacturing and injection molding.Liebherr – a leading German manufacturer of industrial equipment, represented by their aero branch in Toulouse, has collaborated with Aitiip to meet the goal of replacing a metal flange wheel with a flange wheel made in recycled injection-molded high-performance polymer. The ambition: to develop a technology that allows the manufacture of flange wheels for the cooling systems of the aeronautics with 100% recyclable materials. Recognizing that the performance of the chosen polymers would be critical to quality, and that some part features would be more cost-effective to realize with additive manufacturing, Aitiip turned to the NXE 400 and Freeform Injection Molding to meet customer expectations.<h2 id="isPasted">The challenge: &nbsp;Replace metal flange with carbon-filled PEEK, requiring high performance and design complexity</h2><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA5NTIyNjgyMjE0LWFpdGlpcC1jbmMtbWFjaGluZS03Njh4NTEyLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"> Complexity is a cost driver in most manufacturing processes, and manufacturers have been looking to additive manufacturing as a way to simplify the manufacturing of complex objects. In the case of the flange wheel, design complexity challenges were compounded by the ambition to replace metal with a carbon-filled PEEK, a high-performance thermoplastic notoriously difficult to prototype. In the manufacturing of PEEK parts, process parameters need to be tightly controlled to achieve target performance, and Liebherr worked with Aitiip to develop and verify a manufacturing process that would meet the following requirements:<ol><li>High-speed manufacturing process that will lead to 30% cost reductions</li><li>Recyclable materials</li><li>Light-weighting – with a goal of reaching a 40% weight reduction</li><li>One-shot manufacturing</li></ol>The collaboration was carried out within the framework of the INN-PAEK project, which was funded by the Clean Sky 2 Joint Undertaking under the European Union’s Horizon 2020 research and innovation programme under grant agreement Nº 101007865.<blockquote id="isPasted">“The quality, repeatability and freedom offered by the Nexa3D printers and the xMOLD resin has enabled us to create and validate an entirely new on-demand manufacturing paradigm.”– Pablo Murillo, Aitiip</blockquote><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA5NTIyNzM4MDkwLTE3MDk1MjI3MzgwOTAucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dib"><h2 id="isPasted">The solution: Integration of Additive Manufacturing and Injection Molding</h2><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA5NTIyNzYwNTY0LW9uLWRlbWFuZC1pbmplY3Rpb24tbW9sZGluZy1pbXBlbGxlci0xLTc2OHgxMzY1LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"> The part to be manufactured was a complex flange wheel with a challenging load case. To achieve the required part performance and manufacturing speed, injection molding was chosen as the manufacturing method. However, the complexity of the flange wheel would be impossible to achieve with conventional metal tooling.In order to meet Liebherr requirements, Aitiip decided to fully exploit the capabilities of the NXE 400 system in a highly innovative approach:<ol><li>Using the NexaX Pro software, Aitiip created a unique printer profile to enable the printing of parts with superior surface quality</li><li>The impeller body inner geometry was realized with a single soluble 3D-printed FIM insert in the Nexa3D xMOLD printed tooling resin</li><li>One particular part feature was realized with an insert printed in the Nexa3D xPEEK material that was mounted in the soluble insert before injection to enable its full integration into the injection-molded impeller part.</li><li>The 3D-printed FIM insert, with the xPEEK feature, was mounted in a mold cavity. Subsequently, the carbon reinforced PEEK material was injected to fill the cavity, and the 3D-printed FIM insert was dissolved to release the final PEEK part</li></ol><h2 id="isPasted">The benefits: On-demand injection molding of complex impeller enabled and verified</h2><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA5NTIyNzc4MDQyLUludGVncmF0aW9uLUFkZGl0aXZlLU1hbnVmYWN0dXJpbmctYW5kLUluamVjdGlvbi1Nb2xkaW5nLTc2OHg1NzYuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"> Freeform Injection Molding, combined with high-performance xPEEK inserts, enabled Aitiip to meet manufacture a high-performance recycled injection-molded metal replacement part. Furthermore, Aitiip could verify the performance of the part before investments in tooling had to be made.Early Verification: The use of 3D-printed xMOLD resin tooling enabled Aitiip to manufacture a number of test parts, and to use these parts to verify key design and performance aspects.Cost and time savings: FIM has allowed Aitiip weekly iterations, in consequence reducing the project frame time reaching better and more advanced results in comparison to traditional mold making processes.Also, the research cost has been drastically reduced, making more efficient the use of resources (time, cost, material and most importantly human resources) while increasing freedom of design.Seamless scalability: The first iterations were carried out in smaller 3D-printed molds to ensure shortest possible iterations at lowest possible costs. Once the part design had been validated and part performance had been verified, Aitiip proceeded to implement a metal cavity to reduce unit costs while still using a 3D-printed xMOLD core and an xPEEK insert to avoid costly investments in complex slider functionality. The resulting mold concept meets customer requirements at the lowest achievable costs of ownershipRapid iterations: The ability to rapidly and cost-effectively test out a number of tool concepts was a key element in the ultimate success of the project. The complex design of the part, combined with the complex processing of the carbon-filled PEEK, and with the added challenge of integrating a 3D-printed xPEEK insert in an injection-molded part, would have made this project very hard and costly to realize with conventional metal tooling, due to the substantial investments involved<h2 id="isPasted">Customer Impact: Metal replacement, increased recyclability enabled</h2><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA5NTIyNzkxOTk4LWluY3JlYXNlZC1yZWN5Y2xhYmlsaXR5LWVuYWJsZWQtNzY4eDU3Ni5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"> Aerospace parts manufacturers are met with rigorous part quality requirements, and lighter weight is always an objective. In addition, manufacturers seek ways to increase the implementation of recycled materials.Liebherr wanted to explore a lighter-weight alternative to the metal that was used in the manufacturing of a high-performance flange wheel, and collaborated with Aitiip to develop and verify a part design and manufacturing process that would enable Liebherr to migrate from metal to recycled polymer.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA5NTIyODA4NzQ0LWFpdGlpcC0zZC1wcmludGVkLWluamVjdGlvbi1tb2xkLXRvb2xpbmctNzY4eDU3Ni5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib">In successfully completing this project, Aitiip provided Liebherr with the following key output:<ol><li>A verified protocol for the manufacturing of a specific challenging spare part which allows Liebherr to reduce costs, lead-times and supply chain vulnerabilities</li><li>A reference study demonstrating the performance achievable with novel 3D-printed injection mold tooling concepts and novel 3D-printer resins</li><li>A reference model for high mix / low volume product development, scale-up and after-market servicing based on an on-demand manufacturing platform, as an alternative to on-stock supply chain paradigms</li><li>To learn more about Freeform Injection Molding and the experience of Aitiip, please consult the <a href="https://www.aitiip.com/innpaek.html" target="_blank" rel="noopener">INN-PAEK website</a>. You may also want to download the 3D Printed Tooling Design Guide or reach out for more information.</li></ol>

Complexity is a cost driver in most manufacturing processes, and manufacturers have been looking to additive manufacturing as a way to simplify the manufacturing of complex objects.

Aitiip Integrates Freeform Injection Molding to Lower Weight and Reduce Production Costs

The glass transition temperature (Tg) is a fundamental property that allows us to predict, understand and manipulate the performance of polymer materials.

Polypropylene Glass Transition Temperature

Discover the top injection molding materials for high-quality and efficient production. Choose from a wide range of options for your project needs.

Injection Molding Materials

Whether you're an experienced engineer, student or enthusiast, you'll likely be wondering what an <a href="https://www.protolabs.com/en-gb/services/injection-moulding/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-im-0224&utm_content=wevolver-anatomy-of-a-mould-blog-0224" target="_blank">injection mould</a> tool consists of. In this comprehensive guide, we will delve deep into the anatomy of a mould tool, unravelling its components, functions, and the process that occurs when it's in action. <h2>What are the different block sizes for injection moulding?</h2>The specific block sizes used in injection moulding vary based on a number of factors including mould design, machine specifications, material requirements, and the dimensions of the final product being manufactured. Here at Protolabs we can produce parts within the following dimensions. &nbsp;Size: 480mm x 980mm &nbsp;Volume: 966,837mm³ &nbsp;Depth: 101mm from parting line with 3° of draft, up to 280mm of the part Projected Mould Area: 112,903mm2 <h3>What are the different elements of an injection mould tool?</h3><img border="0" width="570" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA4OTM4OTA3NTY4LTE3MDg5Mzg5MDc1NjgucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="Protolabs Demo Mould Mould A-Side" class="fr-fic fr-dii">Mould A-side<h3>&nbsp;Mould A-Side</h3>Cavity – the void or negative space within the mould that forms the desired shape of the product being manufactured. Essentially the inverse of the final product. When molten plastic is injected into the mould, it fills the cavity to take on the specific shape and dimensions of the finished product.Clamp Pocket – a feature within the mould that assists in securely holding or clamping the mould halves together during the moulding process.Leader Pin – Used to align and guide the two halves of the mould together during the closing process. These pins are typically cylindrical and are located on one half of the mould, fitting into the holes on the opposite half.Locking Wedge Interface – a mechanism used to secure and tightly seal the two halves of the mould during the injection process. Prevents any mould misalignment or movement whilst the <a href="https://www.protolabs.com/en-gb/materials/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-im-0224&utm_content=wevolver-anatomy-of-a-mould-blog-0224" target="_blank">material</a> is injected into the cavity.Sliding Shutoff – a component within the mould that allows for the creation of undercuts or complex features in the moulded part. It’s used to create internal or external details that cannot bee formed with a simple two-part mould.Sprue Hole – a channel or passage within the mould that allows molten material to be injected into the mould cavity. It’s the entry point into the cavity.<img border="0" width="570" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA4OTM4OTA3NTc3LTE3MDg5Mzg5MDc1NzcucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="Protolabs Demo Mould B-Side" class="fr-fic fr-dii">Mould B-side<h4> </h4><h3>Mould B-Side</h3>Clamp Toe – the area where the clamp force is applied to, in order to ensure the mould remains closed during the injection process.Core – one of two main components used to create a desired shape. The core is the part of the mould that shapes the internal features of the final product. It is the interior surface of the part and creates voids, holes and other internal details.Ejector Pin Holes – small cylindrical recesses or openings in a mould that accommodate ejector pins.Leader Hole – hole used for aligning or guiding components during the assembly or disassembly of the mould.Return Pin Hole – accommodates the return pin. The return pin is used in moulds with moving elements like slides or cores, to retract or return these elements to their initial / starting position at completion of the mould cycle.Side-Action – also known as sliders, lifters, or side cores, are movable components within the mould that create features on the part that would otherwise be impossible or difficult to form using a two-part mould. These side-actions move perpendicularly or at an angle.Side-Action Track – path or guide along which the side-action components move within the mould. The tracks are designed within the mould to facilitate the controlled and precise movement of the side-actions.<img border="0" width="286" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA4OTM4OTA3NTg1LTE3MDg5Mzg5MDc1ODUucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="Protolabs Demo Mould Part" class="fr-fic fr-dii">Part <h3>Part</h3>Clip Feature – a specific part or featured designed into a moulded product that enables it to be attached, secured, or fastened to another component or surface.Cold Slug – a portion of unmelted or partially melted plastic that enters the mould during the early stages of the injection process. Usually occurs when there’s inadequate or inefficient heating and melting of the plastic material in the injection unit.Edge Gate – a gate that allows molten plastic into the mould cavity. It’s called an “edge” gate because it’s positioned at the edge of the part.Sprue – the primary channel or passage through which molten plastic enters the mould cavity. It’s the initial pathway that connects the moulding machine’s nozzle to the runners in the mould.<img border="0" width="286" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA4OTM4OTA3NTkyLTE3MDg5Mzg5MDc1OTIucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="Protolabs Demo Mould Ejector System" class="fr-fic fr-dii">Ejector System&nbsp;<h3>Ejector System</h3>Ejector Pin – used to push or eject the finished part out of the mould cavity, once the moulding process is complete. Ejector pins are located in specifically designed holes or recesses in the mould and extend into the mould cavity and exert force on the part to push it out of the mould.Ejector Plate – a flat plate or section within the mould that contains multiple ejector pin assemblies used to push the finished part out of the mould cavity.Retaining Tab – a specific feature or component designed within a mould to secure or hold a movable part, preventing it from disengaging or moving unintentionally during them moulding process or while the mould is in use.Return Pin – serves the purpose of retracting or returning movable components to their initial or starting positions after a moulding cycle is complete.<img border="0" width="286" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA4OTM4OTA3NTk5LTE3MDg5Mzg5MDc1OTkucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="Protolabs Demo Mould Side-Action Cam" class="fr-fic fr-dii">Side-Action Cam&nbsp;&nbsp;&nbsp;<h3>Side-Action Cam</h3>Guide – assists in directing the movement of a side-action mechanism within the mould.Locking Wedge – a mechanism used to secure or lock the movement of a side-action mechanism within the mould. <h3>What constitutes a well-designed part for injection moulding?</h3>There are many factors to consider when designing a part. Before any design is sent for tooling, you need to perform the <a href="https://www.protolabs.com/en-gb/automated-design-analysis/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-im-0224&utm_content=wevolver-anatomy-of-a-mould-blog-0224" target="_blank">design for manufacturability</a> (DFM) process. This is a systematic process that focuses on optimising a product's design to enable efficient and cost-effective manufacturing. The DFM process involves collaboration between design engineers and manufacturing engineers to identify potential challenges which might impacts the overall quality of the end-product and making refinements in order to overcome these challenges. The main steps in the process are:<ul><li>Design Analysis</li><li>Design Optimisation</li><li>Material Selection</li><li>Prototyping and Testing</li><li>Review</li></ul>But what constitutes a well-designed injection moulded part? There are several critical factors to ensure successful and efficient manufacturing processes.<ul><li>Uniform Wall Thickness – consistent wall thickness throughout, promotes even colling, reduces warp, and minimises sink marks and voids.</li><li>Rounded Corners and Fillets – reduce stress concentration points, minimise material stress and, improve mould filling.</li><li>Ribs and Bosses – ribs provide structural support and bosses serve as mounting points or structural elements.</li><li>Draft Angles – facilitates easy part ejection and minimises the risk of damage or sticking.</li><li>Avoiding Undercuts – to reduce mould complexity, simplify ejection, and minimise production challenges.</li><li>Gating and Venting – gates ensure even flow of material and even filling, whilst vents prevent trapped air or gases.</li><li>Material Selection – crucial for meeting functional requirements, durability, and cost-effectiveness.</li><li>Minimal Texturing – limiting textures surfaces or complex features reduces mould complexity and ejection challenges.</li><li>Surface Finishes – aid in achieving desired aesthetic and functional qualities of a part.</li><li>Consideration of Tolerances – designing within achievable tolerances ensures part consistency and facilitates cost-effective production.</li></ul>A well-designed part not only considers the part’s functional requirements, but also aims to optimise the manufacturing process, reduce production challenges and ensure the final part meets quality standards efficiently and economically. For further information on how you can produce a well designed part with Protolabs, please view our <a href="https://www.protolabs.com/en-gb/resources/design-for-mouldability-toolkit/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-im-0224&utm_content=wevolver-anatomy-of-a-mould-blog-0224" title="Design for Mouldability Toolkit" target="_blank">Injection Moulding Toolkit</a>, which not only explains our advisories and how to avoid them, but also gives further information on designing complex features for moulded parts.&nbsp;&nbsp;

Have you ever wondered what an injection mould tool consists of? Explore our comprehensive guide to learn more about the ins and outs of mould tool anatomy. 

Unveiling the Secrets: The Anatomy of a Mould Tool

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