Tu J17: Assigned
Th J19: Mold PDR
Tu J24: Mold Urethane CDR
Th J26: 3D Printing
Th F09: Mold Urethane Due
Tu F14: UC Canvas Reflection Due
Th F09: Assigned
Tu F14: Injection Molding Simulation Due
Th F16: IM PDR
Tu F21: IM CDR
Th M16: IM Due
Tu M21: IM Canvas Reflection Due
In groups of two, design and manufacture an injection molded part that interfaces with another component.
1. Use urethane casting to prototype and evaluate the part and mold.
2. Design and machine an aluminum mold for injection molding. Injection mold at least 10 copies of your part.
1. At least 2 urethane cast prototypes of your part.
2. At least 10 injection molded copies of your part.
3. Engineering drawings of your part and molds.
- For urethane casting we will print the tool on the ProJet 6000 HD, and you will create the mold.
- For injection molding you will machine your entire mold.
- Parts will be designed to fit within a 5" x 5" x 3" box.
- Your injection molding tooling must have 1" wall thickness in X, Y, and Z.
- Your mold will need a 1/8" deep, 1" diameter concave pocket to accommodate the outside of the nozzle. A 1" ball endmill will be provided.
- The ID of the nozzle is 5/32".
- The following tapered endmills are available for use in creating your molds:
Urethane Mold Making:
- Each team will receive 1kg of BlueStar V-340 Silicone rubber with CA45 Catalyst to make a mold.
- Each team will be allowed to print 2.0 cu. in. on either the ProJet or Objet 3D Printers
- Acrylic/MDF from RPL.
Injection Mold Making:
- 5"x2" Bar stock
Injection Molding Thermoplastic:
- Freeman Supply Video Library
- Morgan Press Manual
- Manufacturing Processes for Design Professionals: Injection Molding
- Design for Manufacturability: Injection Molding
- IPD501 DemoMold_Zhou
- SolidWorks Plastics Guide
- Morgan-Press Operating Instructions
- You created at least three versions of your part during this project: 3D printed, urethane cast, and injection molded. What are the differences between the three versions of your part and how did each influence the final design of your part? What aspects of the final part and process were not enveloped by the two prototype parts?