3D PRINTED

INJECTION MOLDS
CAN YOUR BUSINESS BENEFIT?

MARK BASHOR

1 STRATASYS / COMPANY OVERVIEW

WE ARE

THE 3D PRINTING SOLUTIONS COMPANY

2 STRATASYS / COMPANY OVERVIEW

FROM SYSTEMS
TO SERVICE

3 STRATASYS / COMPANY OVERVIEW

 Today’s Event

Presenter
Mark Bashor, Applications Engineer
Stratasys

4 STRATASYS / COMPANY OVERVIEW

AGENDA: 3D PRINTED INJECTIONS

Where Do 3D Printed Molds Fit?

Business Rationale
Customer Stories
Technical Tips and Tricks for Success
Q&A

5 STRATASYS / COMPANY OVERVIEW

SECTION ONE

WHEN ARE 3D
PRINTED MOLDS
USED?
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 WHICH STAGE?

Part Design Prototype 1 Prototype 2 Manufacturing

CAD software Concept modeling 3D Printed

Rapid prototyping Injection Molds
Simulation Functional
Real End Material*
Full Range Tests
Mold Verification

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VIDEO

01:32
Revolutionizing the Injection Molding Process
Using 3D Printing

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 WHICH PLASTICS?

Based on 2014 customer survey (58% response rate)

500

500

400 300

300
100
200 100
70
40
5 17
100

0
Soft / Elastomeric Plastics Standard Plastics

Uses Min. Max. Avg.

Instances of Use Minimum Part Yield Maximum Part Yield Average Part Yield
The number of times survey The minimum number of parts The maximum number of parts The average number of parts
respondents used PolyJet survey respondents reported survey respondents reported survey respondents reported
molds for this type of plastic producing per tool. producing per tool. producing per tool.

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 IDEAL CONDITIONS

• Use plastics with molding

temperatures up to 300° C
(570° F). Candidates include:

PE, PP, PS, ABS, TPE, PA,

POM, PC-ABS and glass-filled
resins
• Produce mid-sized parts up to
165 cubic centimeters (10
cubic inches)
• Use up to 200-ton molding
machines

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SECTION TWO

BUSINESS
RATIONALE

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 Return on Investment

Very attractive ROI on small,

complex molds when
compared with machined
aluminum molds.

This 3D printed HASCO standard mold insert empowers

low-cost rapid prototypes.

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 Savings vs. Frequency of Use

Based on 2014 customer survey (58% response rate)

600,000

500,000

400,000

300,000

200,000

100,000

0
1-5/week 1-5/month 1-5/quarter 1-5/year
(1 customer) (5 customers) (2 customers) (4 customers)

MAX. MIN.

Estimated Savings Estimated Savings

$2,000 USD per tool $2,000 USD per tool

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SECTION THREE

CUSTOMER
STORIES

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 Diversified Plastics

3D Printer:
Objet260 Connex

Industry:
Custom molding

Need:
Small series production and prototypes from
end-product material.

16 STRATASYS / COMPANY OVERVIEW

VIDEO

03:25
Diversified Plastics Customer Story

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 Worrell

3D Printer:
Objet500 Connex

Industry:
Medical device design house

Need:
Speeding time to market in medical device
product development for their customers

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 Worrell: MedTG

Time (Days)
Traditional Tooling
56

3D Printed Tooling
2

Cost (USD)
Traditional Tooling
11,000

3D Printed Tooling
2,600

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 Worrell: OBMedical

Time (Days)
Traditional Tooling
84

3D Printed Tooling
3

Cost (USD)
Traditional Tooling
12,000

3D Printed Tooling
4,000

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 Unilever

Printer:
Objet500 Connex

Industry:
Consumer Goods

Need:
Prototypes from end-product material;
functional testing on living hinges, caps and
bottles.

22 STRATASYS / COMPANY OVERVIEW

 Unilever

Cost Savings

80% Unilever was able to

produce prototypes at
20% of the usual cost.

Time Savings

50% Unilever can deliver

iterations 50 percent
faster than traditional
model making methods.

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 Unilever

“By 3D printing the injection

molds with Digital ABS, we’re
able to achieve the high quality
associated with traditional
manufactured prototypes, while
ensuring that the high
temperatures and pressures of
the injection molding process
can be sustained.”

Stefano Cademartiri
R&D, CAP and prototyping
specialist at Unilever

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 Seuffer

Printer: Objet30Pro, Objet500 Connex

Industry: Automotive

Need:

• Prototypes from final material

• Functional tests for snap fits

• Electrical components over-molding

25 STRATASYS / COMPANY OVERVIEW

 Seuffer

Time (Days)
Traditional Tooling
56

3D Printed Tooling
2

Cost (Euros)
Traditional Tooling
40,000

3D Printed Tooling

1,000

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VIDEO

02:15
Seuffer Customer Story

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 Grundfos

Printer: Objet500 Connex3

Industry: Pump manufacturing

Need:

• Production-ready prototypes

• Complex mold design with best

surface finish

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 Grundfos

Injection molded part inside PolyJet mold Side view of part with mold and sprue Final part produced from the PolyJet mold

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 Whale

3D Printer: Objet500 Connex3

Industry: Water and heating systems for

mobile applications

Need:

Prototyping in production-grade materials for

faster time to market

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 Whale

“This is revolutionary… I
estimate we’ve shortened our
R&D process up to 35%, and
this is on top of the 20% we’re
already saving on ourdesign
work. For me, it’s fantastic.” PolyJet molds produce intricate details.

Patrick Hurst
Managing Director, Whale

Pump diaphrams created using PolyJet molds.

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SECTION FOUR

TECHNICAL
TIPS & TRICKS
FOR SUCCESS
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 Technical Tips & Tricks for Success

Increase draft angle (2-5°)

• To facilitate ejection

• To reduce stress

Use sprue bushing

• Avoid direct contact between the molding
machine’s nozzle and the PolyJet insert Increase draft angle – 5° recommended.

• Incorporate the sprue in the mold base /

steel plate

• Undersize the hole by 0.2 – 0.3 mm (0.008

– 0.012 in) and ream to size during mold
assembly

Standard sprue bushing.

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 Bolt Holes

Bolt holes (green)

Ejection system (red)

• Add round holes for ejector pins

• Undersize by 0.2 - 0.3 mm

(0.008 – 0.012 in)
Add holes for ejector pins (red).
• Ream to perfect fit

• Keep holes 2 mm (0.08 in) from edges to

prevent thin walls

After 3D printing:

• Ream holes

• Confirm snug but smooth movement

Ream holes for core and ejector pins.

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 Cooling System

• Increase cooling cycle time between shots to

allow the mold to cool to a target temperature of
50 °C (120 °F)

• Accelerate cooling by blowing compressed air

onto the core and cavity

• If cooling channels used, locate 8 – 10 mm (0.315

– 0.394 in) below the cavity surface
Cooling system.

Compressed air cools the core and cavity between cycles.

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 Mold Base Options

MUD base (master unit die – preferred)

• Seat inserts in mold base pockets

• Confirm 0.2 mm (0.008 in.) beyond mold

base

• Mill or add shims to adjust height

Steel plates

• Include or exclude the ejection system MUD base with PolyJet printed mold insert.

• Confirm the mold is 20 - 25 mm (0.75 - 1.0

in) larger than the mold cavity on all sides

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PolyJet molds with steel plates.
 Mounting Options

Mold base (recommended)

• Largest investment

• Improved part quality

• Printed inserts can be smaller (no additional

frame needed)

Steel plate with ejection Mold base (recommended).

• Mid-range investment

• Increased part complexity

Steel plate without ejection

• Smallest investment

• Fastest PolyJet molds mounted on steel plates.

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 Surface preparation

1. Remove support material

2. Smooth surfaces

• For extraction (optional):

Lightly sand surfaces that rise in the
pull direction with 180/220 grit
sandpaper.
Sand vertical surfaces (red) for extraction.
• For appearance (optional):
Lightly sand all surfaces with
180/220 grit followed by 320/400
grit

Sand cosmetic surfaces (green) for appearance.

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 Tool Longevity

Goal: Use conservative settings to extend the

life of the tool.
• Start with very low pressures and
temperatures
• Conduct test runs
• Inspect results
• Adjust as needed

Test shots to dial in injection parameters.

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 Initial settings

Injection molding time limit: 20 seconds

Pack & hold phase: 0 kPa (0 psi) and 0 seconds

Shot size: 75% of standard volume

Barrel temperatures: Low end of resin recommendation

Injection speed:

• Low end of resin recommendation

• 10% to 20% of the machine’s maximum screw speed

Cooling cycle:

• Small, thin parts: 40 seconds

• Larger parts or thicker features: 90 seconds

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 Trial shots

• Increase shot size

Target: 90% of volume

• Adjust packing pressure:

30 – 50% of injection pressure

• Increase hold time

• Try to avoid getting flash

If sink marks are present:

• Adjust barrel temperature

• Adjust injection speed

• Do not over-cool part. This will cause part Threaded cap from mold. Threaded cap from mold.
to shrink and grab tool. 20% GF PP 20% GF PA 6/6

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 Mold Temperature

• Mold temperature will rise with

continuous operation (undesirable)

• Allow to cool between shots

Target: 50 °C (122 °F)

• Measure mold temperature with IR gun

Either:

• Use extended dwell between cycles

• Accelerate with compressed air

during dwell Compressed air cools mold to 50 °C (120 °F).

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 More Information and Resources

www.stratasys.com/webinar-injectionmolding
• Download webinar slides & documents
• View webinar on-demand
• Submit technical questions to engineer

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Questions?
www.stratasys.com/webinar-injectionmolding

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THANK YOU

Mark Bashor
Applications Engineer
Manufacturing Tools, VBU
Rancho Cucamonga, Ca
Mark.Bashor@stratasys.com

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