Modular blow molding system for blow molding containers

Abstract

A modular system for blow molding containers is provided.SOLUTION: The system may include a first portion, a second portion, and a third portion. The first portion and the second portion may each include a shell, a mold removably coupled to the shell, and a top plate. The third portion may include a base and a base mold. The mold may be 3D printed. The molds may collectively define a blow mold cavity. The modular system may be used at laboratory scale, pilot scale, or full production scale. The mold may be durable and smooth enough for full production scale. Some embodiments relate to a method for making a modular system for blow molding containers.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a blowing system for blowing containers. More particularly, embodiments relate to a modular system for blowing containers and methods for making the same. Summary of the Invention

[0002] Some embodiments are directed to a modular system for blow molding a container comprising a first portion, a second portion, and a third portion. The first portion may comprise a first shell, a first mold removably coupled to the first shell, a first top plate removably coupled to the first shell, and a first filler material disposed within a volume defined by the first shell, the first mold, and the first top plate. The second portion may comprise a second shell, a second mold removably coupled to the second shell, a second top plate removably coupled to the second shell, and a second filler material disposed within a volume defined by the second shell, the second mold, and the second top plate. The first mold and the second mold may be 3D printed. The third portion may comprise a base and a base mold. The base may be removably coupled to the first shell and the second shell. When the first part is coupled to the second part, the first mold, the second mold, and the base mold may together define a blow mold cavity.

[0003] In any of the various embodiments disclosed herein, the system further includes a first cavity retainer removably coupled to the first shell and a second cavity retainer removably coupled to the second shell.

[0004] In any of the various embodiments disclosed herein, each of the first mold, the second mold, and the base mold is 3D printed.

[0005] In any of the various embodiments disclosed herein, the first shell, the first top plate, the second shell, and the second top plate are made from CNC machined metal.

[0006] In any of the various embodiments disclosed herein, each of the first mold, the second mold, and the base mold is isotropic.

[0007] In any of the various embodiments disclosed herein, the filler material has a modulus of at least 6300 MPa.

[0008] In any of the various embodiments disclosed herein, the first mold, the second mold, and the base mold are made from a polymer that includes a cyanate ester.

[0009] In any of the various embodiments disclosed herein, the system further comprises at least one cooling channel within each of the first mold and the second mold.

[0010] In any of the various embodiments disclosed herein, the system further includes a locking ring removably coupled to the first shell, and the base is configured to releasably engage the locking ring to secure the third portion.

[0011] In any of the various embodiments disclosed herein, the system further comprises a plurality of vertically aligned recesses configured to receive locking rings such that the vertical position of the third portion can be adjusted.

[0012] In any of the various embodiments disclosed herein, the first shell, the first top plate, the second shell, and the second top plate are made from CNC machined metal.

[0013] Some embodiments are directed to an interchangeable mold for blow molding a container. The mold may include a first 3D-printed mold section, a second 3D-printed mold section, and a 3D-printed base section. The first 3D-printed mold section, the second 3D-printed mold section, and the 3D-printed base mold section may together define a blow mold cavity. The first 3D-printed mold section, the second 3D-printed mold section, and the 3D-printed base section may be isotropic. The first 3D-printed mold section, the second 3D-printed mold section, and the 3D-printed base section are configured to engage with a shell, and the shell is compatible with a blow molding system to form a blow-molded container within the blow mold cavity.

[0014] In any of the various embodiments disclosed herein, the first filler portion comprises a first side configured to mate with the back surface of the first 3D printed mold part and a second side configured to mate with the interior side of the shell. In any of the various embodiments disclosed herein, the second filler portion comprises a first side configured to mate with the back surface of the second 3D printed mold part and a second side configured to mate with the interior of the shell.

[0015] In any of the various embodiments disclosed herein, the first 3D printed mold part, the second 3D printed mold part, and the 3D printed base mold part are made from a polymer that includes a cyanate ester.

[0016] In any of the various embodiments disclosed herein, the mold further comprises a first filler material portion and a second filler material portion, wherein the first filler material portion has a first side that contacts the back surface of the first 3D printed mold part and a second side that is configured to contact the inner side of the shell, and the second filler material portion has a first side that contacts the back surface of the second 3D printed mold part and a second side that is configured to contact the inner side of the shell.

[0017] In any of the various embodiments disclosed herein, the first filler material and the second filler material are both plaster.

[0018] In any of the various embodiments disclosed herein, the first mold section and the second mold section each include a cooling channel.

[0019] In any of the various embodiments disclosed herein, the mold further comprises a first cavity retainer and a second cavity retainer for securing the first filler portion and the second filler portion, respectively.

[0020] In any of the various embodiments disclosed herein, the mold further comprises a first cavity retainer and a second cavity retainer for securing the first filler portion and the second filler portion, respectively.

[0021] Some embodiments are directed to a method of making a modular blow molding system, the method including: 3D printing a first mold section, a second mold section, and a base section; coupling the first mold section to a first shell to form a first half, the first half including a first volume defined by the first mold section and the first shell; coupling the second mold section to the second shell to form a second half, the second half including a second volume defined by the second mold section and the second shell; injecting a fill material into the first volume; injecting the fill material into the second volume; and cooling the fill material to form a solid fill material.

[0022] In any of the various embodiments disclosed herein, the first mold part, the second mold part, and the base part are made from a polymer that includes a cyanate ester.

[0023] In any of the various embodiments disclosed herein, the filler material comprises plaster.

[0024] In any of the various embodiments disclosed herein, the plaster is a liquid before cooling.

[0025] In any of the various embodiments disclosed herein, the cooling comprises cooling the fill material at room temperature.

[0026] In any of the various embodiments disclosed herein, the 3D printing step includes forming at least one channel in the first mold part and the second mold part.

[0027] In any of the various embodiments disclosed herein, the method further includes joining the first half and the second half to form a blow mold including a blow mold cavity defined by the first mold portion and the second mold portion. [Brief explanation of the drawings]

[0028] [Figure 1] 1 shows one half of a modular blow molding system coupled to a base portion. [Figure 2] 2 shows the assembled modular blow molding system of FIG. 1. [Figure 3] 2 shows an exploded view of one half of the modular system and base portion of FIG. 1. [Figure 4] 4 shows a cross-sectional view of one half of the modular system of FIG. 1 with filler material, taken along line 4-4 of FIG. 1. [Figure 5] 5 shows a cross-sectional view of one half of the modular system of FIG. 1 taken along line 5-5 of FIG. 1. [Figure 6] 6 shows a flow chart illustrating a method for assembling the modular blow molding system of FIGS. [Figure 7] 6 shows a flowchart illustrating a method for manufacturing the modular blow molding system of FIGS. 1 to 5. DETAILED DESCRIPTION OF THE INVENTION

[0029] Some blow molding systems (e.g., shell molds, hot-fill molds, full-body molds, and small-cavity mold systems) use components generated using computer-aided design (CAD) / computer-aided manufacturing (CAM) systems. These systems can use laser engraving or etching for intricate design features. These systems can be expensive and require a significant amount of time to manufacture after design. These systems can be used to make beverage containers using a blow molding process, which involves placing a preform into a mold. The preform is heated, and then air is blown into the preform to blow the heated preform material and form a container that conforms to the shape of the mold.

[0030] However, developing a new container design can be an iterative process. This design process can involve creating multiple new molds as the design is conceived, developed, and refined. Adapting this iterative process can be a long and expensive process for existing blow molding systems. And the time required to produce the next iteration can delay the production cycle so that multiple iterations may not be economically viable. Therefore, with existing blow molding systems, cost and time can prevent the production of one or more molds before a full-scale production model is produced.

[0031] While attempts have been made to use 3D printing in blow molding systems, these existing systems are only suitable for laboratory-scale processes and result in poor surface quality and short life cycles (typically only a few hundred bottles can be produced before failure) due to their low strength. This low strength and poor surface quality make these systems suitable only for very early, small-scale production for consumer or mechanical testing. Additionally, existing 3D printing for blow molding systems use additive techniques to produce polymer-based components, using materials such as acrylonitrile butadiene styrene (ABS). However, the additive techniques used result in molds with poor surface quality for the resulting containers. Due to these issues, these 3D printed molding systems are not suitable for scaling up beyond laboratory-scale processes. Therefore, existing 3D printed molding systems are generally suitable for low-volume runs during initial design testing.

[0032] Therefore, there is a need for a 3D printing blow molding system that is cost-effective, improves the surface quality of the resulting container, can withstand high temperatures and pressures, and is durable enough to be used reliably in larger scale applications (e.g., pilot or full production scale). Further, there is a need for a system that has these advantages and is modular and interchangeable, allowing it to be integrated into existing production lines.

[0033] Using the blow molding systems according to embodiments disclosed herein, it is possible to produce modular blow molding systems that reduce tooling costs and minimize lead time for each container design and each iteration of the design process. Furthermore, the blow molding systems disclosed herein can be used in pilot-scale and production-scale processes. Furthermore, the embodiments disclosed herein include interchangeable molds, allowing portions of the blow molding system to be reused each time a new bottle design is used. These molding systems also allow for iterations of prototype creation for new bottle designs while improving strength, flexibility, and surface quality.

[0034] The modularity of the disclosed systems also allows the systems (e.g., modular blow molding system 100) to accommodate a variety of bottle sizes and concepts, providing for rapid changeover of designs before a final design is locked in. Additionally, the molding systems disclosed herein are capable of producing bottles with surface quality sufficient for pilot or even full production scale, but may also have the capacity to produce millions of bottles. The same system (e.g., modular blow molding system 100) can be used across different platforms, from laboratory scale to full production scale.

[0035] All of these advantages result in accelerated production times and a much more flexible blow molding system. For example, after a new container is designed, a new mold can be ready for use within 1-2 weeks, compared to the 4-5 weeks it takes for existing systems to be ready for use. It can also reduce the manufacturing cost of each mold by as much as 80-90%.

[0036] As shown throughout all figures, modular blow molding system 100 may include a first portion 105, a second portion 110, and a base 115. In some embodiments, first portion 105 and second portion 110 are mirror images of each other (possibly with differences in the mold cavity depending on the bottle design). While some embodiments disclosed herein are described with reference to first portion 105, it should be understood that all descriptions of first portion 105 also apply to second portion 110. For example, all components present on first portion 105 may have corresponding components on second portion 110, and second portion 110 may have the same functionality as first portion 105.

[0037] 1 shows a first portion 105 of a modular blow molding system 100 coupled to a base portion 900. The first portion 105 may include an outer shell 200, a mold section 300, a retainer plate 400, a top plate 500, a cavity retainer 700, and a locking ring 800 (see, e.g., FIG. 3). The second portion 110 may include corresponding components (e.g., the outer shell 210 and top plate 510 shown in FIG. 2, as well as the mold section, retainer plate, cavity retainer, and locking ring). The base 115 may include a base portion 900 and a base mold section 310.

[0038] Figure 2 shows modular blow molding system 100 when first portion 105, second portion 110, and base 115 are assembled. As shown in Figure 2, when assembled, mold portions (e.g., mold portion 300 and base mold portion 310) form an opening 1000 and a blow mold cavity within modular blow molding system 100. Opening 1000 may be sized to receive a preform (e.g., preform 1200, see Figure 4). The blow mold cavity may correspond to the shape of the container to be blown.

[0039] Figure 3 shows an exploded view of the first portion 105 of the modular blow molding system 100. Each of these components is discussed in detail below. Figure 4 shows a cross-sectional view of the first portion 105, base mold section 310, and base portion 900 of the modular blow molding system 100 along line 4-4 shown in Figure 1. Figure 5 shows a cross-sectional view of the first portion 105, base mold section 310, and base portion 900 of the modular blow molding system 100 along line 5-5.

[0040] One advantage of the disclosed system is its versatility. The modular blow molding systems disclosed herein (e.g., modular blow molding system 100) may be capable of accommodating any of a variety of container shapes or sizes, but may also be compatible with existing blow molding systems. For example, modular blow molding system 100, when assembled, may be the same size as a conventional blow molding system. Additionally, modular blow molding system 100 may be used at laboratory scale, pilot scale, or full production scale.

[0041] The modular systems disclosed herein (e.g., modular blow molding system 100) also improve flexibility. For example, certain components can be reused regardless of the shape or size of the container mold. For example, outer shells 200 and 210, retainer plates (e.g., retainer plate 400), top plates 500 and 510, locking rings (e.g., locking ring 800), and base portion 900 may be reusable components. These reusable components may be made of metal. In some embodiments, the reusable components are computer numerically controlled ("CNC") machined metal.

[0042] Other components, such as mold sections (e.g., mold section 300 and base mold section 310) and cavity retainers (e.g., cavity retainer 700), may be interchangeable. The interchangeable components may be compatible with reusable components. For example, mold sections (e.g., mold section 300) and base mold section 310 may together form a mold corresponding to a bottle shape. Any bottle shape may be created by simply replacing the mold sections (e.g., mold section 300 and base mold section 310) with a different mold that is compatible with the reusable components. In some embodiments, the interchangeable components are 3D printed using a polymer. For example, the interchangeable components may be 3D printed using a cyanate ester. In some embodiments, the interchangeable components are 3D printed using a metal. For example, the interchangeable components may be made of 3D printed aluminum alloy, bronze alloy, or stainless steel. The 3D printed components may be fully isotropic. Unlike layered 3D printing methods, which can introduce failure points in each layer, fully isotropic components can increase strength and improve surface quality. As used herein, "isotropic" refers to a material whose mechanical and thermal properties (e.g., modulus of elasticity, compressive strength) are the same in all material directions. After 3D printing, the replaceable components may be further processed. In some embodiments, the replaceable components are washed and cured in a temperature-controlled chamber.

[0043] The outer shell 200 may have a mold contact surface 203, a top plate contact surface 204, an inner surface 205, and an outer surface 206. The outer shell 200 may also have a recess 201 and a recess 202.

[0044] The mold section 300 may include a container mold section 302 and a flange 303. The flange 303 may contact a mold contact surface 203 on the outer shell 200. The mold section 300 may be secured to the outer shell 200 where the flange 303 and mold contact surface 203 meet using screws. When the mold section 300 is coupled to the outer shell 200, a space is formed between the inner surface 205 and the container mold section 302. The container mold section 302 may be shaped specifically for the container or may be redesigned as needed to accommodate different container designs and sizes. The shape and size of the portion of the flange 303 that contacts the mold contact surface 203 may remain the same even if the size and shape of the container mold section 302 is adjusted. This allows the mold section 300 to easily engage with the outer shell 200. In some embodiments, a retainer plate 400 and a top plate 500 are used to secure the mold section 300 to the outer shell 200. For example, retainer plate 400 may be placed on flange 303, and screws may be used to secure together outer shell 200, mold sections 300, and retainer plate 400. Screws 501 may then be used to secure the top plate.

[0045] The top plate 500 may be shaped to seat on the top plate contact surface 204 of the outer shell 200. The top plate 500 may be coupled to the outer shell 200 using screws. The outer shell 200, mold sections 300, and top plate 500 together form a volume 1100 (see, e.g., FIGS. 4 and 5). In some embodiments, the volume 1100 remains empty during use. In some embodiments, a filler material is used to fill the volume 1100. For example, the filler material may be a filler material 600, which is described in more detail below.

[0046] Cavity retainer 700 may be positioned to surround volume 1100 (and, in embodiments where filler material 600 is used, secure filler material 600 within volume 1100). For example, cavity retainer 700 may be coupled to outer shell 200. In some embodiments, cavity retainer 700 includes a flange 701 that mates with a corresponding recess 201. Locking ring 800 may be coupled to outer shell 200. When coupled, locking ring 800 engages one of the recesses 202, providing a method of coupling base mold section 310 and base section 900 to first section 105. Cavity retainer 700 and locking ring 800 may be moved up or down to accommodate molds for containers having different heights. For example, for shorter containers, cavity retainer 700 and locking ring 800 may be coupled using the top recesses 201 and 202, respectively.

[0047] In some embodiments, second part 110 has the same parts as first part 105. In some embodiments, all of the components of second part 110 are mirror images of the corresponding parts of first part 105. For example, second part 110 can include outer shell 210, top plate 510, mold sections, a retainer plate, a filler material, a cavity retainer, and a locking ring, which are mirror images of outer shell 200, mold sections 300, retainer plate 400, top plate 500, filler material 600, cavity retainer 700, and locking ring 800, respectively. In some embodiments, second part 110 is a mirror image of first part 110, except for differences in the mold cavity depending on the bottle design. Second part 110 can be bonded to first part 105 and base 115.

[0048] The base 115 of the modular blow molding system 100 can include a base portion 900 and a base mold portion 310. The base mold portion 310 can be a mold corresponding to the base of the container. The base mold portion 310 can be interchangeable based on the desired container base shape. The base mold portion 310 can be coupled to the base portion 900 using pins (e.g., pin 311) to form the base 115. The base 115 can be coupled to the first portion 105 and the second portion 110 to form the modular blow molding system 100. When the first portion 105, the second portion 110, and the base 115 are coupled, the mold portions (e.g., mold portion 300 and base mold portion 310) form a blow mold cavity corresponding to the shape of the container.

[0049] Blow molding system 100 may include opening 1000. In some embodiments, opening 1000 is configured to receive a preform for a container (e.g., preform 1200), as shown in Figure 4. The preform may be a standard preform for producing blow-molded containers. The preform may be made from any type of blow-moldable plastic (e.g., PET).

[0050] The mold sections (e.g., mold section 300 and base mold section 310) and cavity retainers (e.g., cavity retainer 700) may be made from any suitable 3D printing material. To improve mold stability and thermal properties, the 3D printed material may have a high modulus of elasticity and a high heat distortion temperature, while also providing a sufficiently smooth and durable surface to provide a consistent, high-quality container surface. The mold sections (e.g., mold section 300 and base mold section 310) may be made from a material having a tensile strength of at least 50 MPa (e.g., at least 75 MPa or at least 90 MPa), a modulus of elasticity of at least 2500 MPa (e.g., at least 3000 MPa or at least 3500 MPa), and a heat distortion temperature of at least 200°C (e.g., at least 225°C or at least 250°C). In some embodiments, the 3D printing material is a cyanate ester. In some embodiments, the 3D printing material is a metal. In some embodiments, the mold sections (e.g., mold section 300 and base mold section 310) and the cavity retainer (e.g., cavity retainer 700) are made from the same material. In some embodiments, the mold section (e.g., mold section 300) is made from a different material than the base mold section 310. For example, the 3D printing material can be a polymer or a metal. In some embodiments, the 3D printing material is a cyanate ester.

[0051] The filler material 600 can further increase the strength of the modular blow molding system 100. During the blow molding process, the mold is subjected to pressure from within the blow mold cavity. Existing systems use molds made of metals (e.g., steel) that can withstand pressure changes, or 3D printed molds that tend to warp or compress during blow molding, which reduces the overall lifespan and quality of the mold. The embodiments disclosed herein use strong 3D printed materials (e.g., the isotropic materials described above) to withstand the pressure. The filler material (e.g., filler material 600) can further increase the strength of the mold because it is relatively incompressible, helping the mold support the internal pressure without warping.

[0052] In some embodiments, the filler material 600 also improves the thermal properties of the modular blow molding system 100. The filler material 600 may be an injectable plaster that is poured into the volume 1100. The filler material may have a high modulus of elasticity and high compressive strength. After injection, the filler material 600 may solidify. In some embodiments, the filler material 600 may have a modulus of elasticity of 900 kg / m 3 ~1500kg / m 3 In some embodiments, the filler material 600 is a plaster having a density of about 1200 kg / m 3 The filler material 600 may have a modulus of elasticity. In some embodiments, the filler material 600 may have a modulus of elasticity of at least 5600 MPa (e.g., at least 6300 MPa, at least 7000 MPa). In some embodiments, the filler material 600 has a modulus of elasticity between 5600 MPa and 8400 MPa (e.g., between 6300 MPa and 7700 MPa). In some embodiments, the filler material 600 has a modulus of elasticity of about 7000 MPa.

[0053] Because operating conditions can include elevated temperatures, regulating temperature can be beneficial during blow molding. For example, in some embodiments, the temperature of a mold section (e.g., mold section 300 or base mold section 310) may be regulated by including internal cooling channels, which are optionally provided to improve cooling efficiency. In some embodiments, each mold section (e.g., mold section 300) includes at least one cooling channel (e.g., channel 301). In some embodiments, a mold section (e.g., mold section 300) includes at least three cooling channels (e.g., cooling channel 301) configured to receive a cooling fluid. In some embodiments, the cooling channels (e.g., channel 301) are vertically oriented, conformal cooling channels, as illustrated by the cross-section shown in FIG. 5 . In use, a gas or liquid can be flowed through the cooling channels to improve cooling of the mold section (e.g., mold section 300). In some embodiments, a coolant is flowed through the cooling channels. In some embodiments, flowing a coolant through the cooling channels improves productivity of blow molding system 100.

[0054] The modular blow molding systems disclosed herein (e.g., modular blow molding system 100) can be durable enough to be used at a pilot scale and have a life cycle equivalent to at least 5,000 containers (e.g., at least 7,500 containers, at least 10,000 containers, at least 15,000 containers). In some embodiments, modular blow molding system 100 is durable enough to be used at a production scale and has a life cycle equivalent to at least 100,000 containers (e.g., at least 250,000 containers, at least 500,000 containers, at least 1,000,000 containers, or at least 2,000,000 containers).

[0055] The modular blow molding system 100 can be easily assembled and disassembled. The steps for assembling the blow molding system 100 are shown in the flowchart of FIG. 6. The first section 105 can be assembled in steps 3000 to 3400. In step 3000, the mold section 300 is positioned so that the flange 303 of the mold section 300 is aligned with the mold contact surface 203 of the outer shell 200. Next, in step 3100, the retainer plate 400 is positioned so that it covers the flange 303 of the mold section 300 from above. Screws can be used to connect the outer shell 200, the mold section 300, and the retainer plate 400. In step 3200, the top plate 500 is fixed to the outer shell 200 using screws at the top plate contact surface 204. Next, the locking ring 800 is connected to the outer shell 200 in one of the recesses 202. The position of the locking ring 800 can be adjusted depending on the height of the container to be blow-molded. If a filler material is used, the filler may be created in optional step 3300. Methods for creating filler material 600 are discussed in detail below in step 4200. In some embodiments, no filler material is used. In step 3400, cavity retainer 700 is bonded to outer shell 200 in recess 202. Steps 3000-3400 can be repeated to assemble second portion 110.

[0056] In step 3500, base mold section 310 can be coupled to base section 900 to form base 115. Next, in step 3600, base 115 is coupled to first section 105 by locking ring 800. After base section 900 is coupled to first section 105, in step 3700, second section 110 may be coupled to first section 105 to form assembled modular blow molding system 100. When first section 105 and second section 110 are coupled, modular blow molding system 100 forms a blow mold cavity defined by each of the mold sections (e.g., mold section 300 and base mold section 310).

[0057] The components of the modular blow molding system can be fabricated using a variety of methods. For example, in step 4000, the reusable components may be fabricated from metal using CNC machining. The reusable components may include outer shells 200 and 210, a pair of cavity retainer plates (e.g., retainer plate 400), top plates 500 and 510, a locking ring (e.g., locking ring 800), and base portion 900. In step 4100, the replaceable components (e.g., mold section 300, base mold section 310, and cavity retainer 700) may be fabricated using 3D printing. In some embodiments, the replaceable components are fabricated from a polymer (e.g., cyanate ester). In some embodiments, the replaceable components are fabricated from a metal. For example, the replaceable components may be fabricated from a 3D printed aluminum alloy, bronze alloy, or stainless steel.

[0058] In step 4200, fill material 600 can be formed. Forming fill material 600 can include first bonding outer shell 200, mold sections 300, retainer plate 400, and top plate 500, as described in steps 3000-3300 above. Once these components are assembled, the assembled components can be inverted so that top plate 500 is facing downward. Liquid fill material 600 can then be poured into volume 1100 defined by outer shell 200, mold sections 300, and top plate 500. In some embodiments, liquid fill material 600 is poured until volume 1100 is filled. After volume 1100 is filled, liquid fill material 600 can be allowed to form a solid (e.g., harden). For example, the fill material can be allowed to cool naturally (e.g., at room temperature conditions), during which time it hardens by transitioning to a solid form. In some embodiments, hardening can occur in a temperature-controlled chamber (e.g., an oven). In some embodiments, the filler material 600 is a liquid plaster that transitions to a solid (e.g., hardened) plaster (e.g., the filler material 600 hardens to form a solid plaster). In some embodiments, the filler material is not hardened at an elevated temperature, but is allowed to cool at room temperature.

[0059] As used herein, terms such as "top," "inside," "outside," and the like are intended to aid in understanding embodiments of the present disclosure with reference to the accompanying drawings with respect to the orientation of the beverage stopper as shown, and are not intended to limit the scope of the present disclosure or to restrict the scope of the present disclosure to the embodiments depicted in the drawings. Directional terms are used for convenience of description, and it is understood that both the stopper and the container may be positioned in any of a variety of orientations.

[0060] As used herein, the term "3D printing" refers to a method of using a digital model to create a physical object by bonding or solidifying printed material into the shape of that physical object.

[0061] As used herein, when the term "about" is used in describing a value or endpoint of a range, it should be understood that the disclosure includes the specific value or endpoint referred to. Whether or not a numerical value or endpoint of a range is described as "about," it is intended to include two embodiments of the range: one modified by "about" and one not modified. As used herein, the term "about" can include ±10%.

[0062] It is understood that the "Detailed Description" section, and not the "Summary" and "Abstract" sections, are intended to be used to interpret the claims. The "Summary" and "Abstract" sections may set forth one or more, but not all, exemplary embodiments of the disclosure as contemplated by the inventors, but are in no way intended to limit the scope of the disclosure and the appended claims.

[0063] This disclosure has been described above with the aid of functional building blocks illustrating the implementation of certain functions and relationships thereof. The boundaries of these functional building blocks have been arbitrarily defined herein for the convenience of description. Alternative boundaries can be defined so long as the specified functions and relationships thereof are appropriately performed.

[0064] The foregoing description of specific embodiments will enable others, by applying their knowledge, to readily modify and / or adapt such specific embodiments to various uses and to make fully apparent the general nature of the present disclosure without undue experimentation and without departing from the general concepts of the present disclosure. Such adaptations and modifications are therefore intended to be within the meaning and range of equivalents of the disclosed embodiments, based on the teaching and guidance presented herein. It is to be understood that the phraseology or terminology used herein is for the purpose of description and not of limitation; consequently, the terminology or terminology used herein should be interpreted by those skilled in the art in the light of the teaching and guidance.

[0065] References herein to "one embodiment," "an embodiment," "an example embodiment," "some embodiments," etc., indicate that the described embodiment may include a particular feature, structure, or characteristic, but that not all embodiments necessarily include the particular feature, structure, or characteristic. Moreover, such phrases do not necessarily refer to the same embodiment. Furthermore, when a particular feature, structure, or characteristic is described in connection with one embodiment, the impact of such feature, structure, or characteristic on other embodiments, whether explicitly stated or not, is intended to be within the knowledge of one of ordinary skill in the art.

[0066] The breadth and scope of the present disclosure should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.

Claims

1. 1. A modular system for blow molding a container, said system comprising: A first portion, a first shell; a first mold removably coupled to the first shell; a first top plate removably coupled to the first shell; a first filler material disposed within a volume defined by the first shell, the first mold, and the first top plate; a first portion comprising: a second portion removably coupled to the first portion, a second shell; and a second mold removably coupled to the second shell; a second top plate removably coupled to the second shell; a second portion comprising: a second filler material disposed within a volume defined by the second shell, the second mold, and the second top plate; a third part including a base and a base mold, the base being removably coupled to the first shell and the second shell; Equipped with When the first part is coupled to the second part, the first mold, the second mold, and the base mold together define a blow mold cavity.

2. The system of claim 1 , further comprising a first cavity retainer removably coupled to the first shell and a second cavity retainer removably coupled to the second shell.

3. The system of claim 2 , wherein each of the first mold, the second mold, and the base mold is 3D printed.

4. The system of claim 3 , wherein the first shell, the first top plate, the second shell, and the second top plate are made of CNC machined metal.

5. The system of claim 3 , wherein each of the first mold, the second mold, and the base mold is isotropic.

6. The system of claim 1 , wherein the first filler material and the second filler material each have a modulus of elasticity of at least 6300 MPa.

7. The system of claim 1 , wherein the first mold, the second mold, and the base mold are made from a polymer including a cyanate ester.

8. The system of claim 1 , further comprising at least one cooling channel within each of the first mold and the second mold.

9. further comprising a locking ring removably coupled to the first shell; The system of claim 1 , wherein the base is configured to releasably engage the locking ring to secure the third portion.

10. 10. The system of claim 9, further comprising a plurality of vertically aligned recesses configured to receive the locking ring such that the vertical position of the third portion can be adjusted.

11. 1. An exchangeable mold for blow molding a container, comprising: a first 3D printed mold part; a second 3D printed mold part; and a 3D printed base mold part; Equipped with the first 3D printed mold section, the second 3D printed mold section, and the 3D printed base mold section are configured to together define a blow mold cavity; the first 3D printed mold part, the second 3D printed mold part, and the 3D printed base mold part are isotropic; A mold, wherein the first 3D printed mold section, the second 3D printed mold section, and the 3D printed base mold section are configured to engage with a shell, the shell being compatible with a blow molding system to form a blow-molded container in the blow mold cavity.

12. 12. The mold of claim 11, wherein the first 3D printed mold part, the second 3D printed mold part, and the 3D printed base mold part are made from a polymer comprising a cyanate ester.

13. a first filler portion having a first side that contacts the back surface of the first 3D printed mold portion and a second side that is configured to contact the interior of the shell; and a second filler portion having a first side that contacts the back surface of the second 3D printed mold portion and a second side that is configured to contact the interior of the shell; The mold of claim 11 further comprising:

14. 14. The mold of claim 13, wherein the first filler material and the second filler material are both plaster.

15. The mold of claim 13 further comprising a first cavity retainer and a second cavity retainer for securing the first filler portion and the second filler portion, respectively.

16. The mold of claim 11 , wherein the first 3D printed mold part and the second 3D printed mold part each include cooling channels.

17. 1. A method of making a modular blow molding system, comprising: 3D printing a first mold section, a second mold section, and a base section; coupling the first mold part to a first shell to form a first half, the first half including a first volume defined by the first mold part and the first shell; coupling the second mold section to a second shell to form a second half, the second half including a second volume defined by the second mold section and the second shell; injecting a filler material into the first volume; injecting the filler material into the second volume; and cooling the filler material to form a solid filler.

18. 20. The method of claim 17, wherein the first mold part, the second mold part, and the base part are made from a polymer that includes a cyanate ester.

19. The method of claim 17 , wherein the filler material comprises plaster.

20. 20. The method of claim 19, wherein the plaster is liquid until cooled.

21. 18. The method of claim 17, wherein the cooling comprises cooling the fill material at room temperature.

22. 20. The method of claim 17, wherein the 3D printing step includes forming at least one channel in the first mold part and the second mold part.

23. 18. The method of claim 17, further comprising joining the first half and the second half to form a blow mold including a blow mold cavity defined by the first mold part and the second mold part.

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