An apparatus for producing multi-material moulds and its process

Abstract

The present invention relates to a mould for producing different types of parts or objects. The mould comprises a main body formed from at least two sections (1) having a thin-walled structure with a thickness between 1.25 mm and 12 mm. The sections (1) are configured for assembly using alignment structures (3) positioned along their periphery. One or more injection ports or pour holes (5), or a combination thereof, are included for introducing moulding material into the mould. The design supports efficient production, reduced weight and material consumption, and is particularly suitable for use with additive manufacturing technologies, enabling rapid fabrication, prototyping, and small-scale production with high accuracy and minimal waste.

Description

AN APPARATUS FOR PRODUCING MULTI-MATERIAL MOULDS AND ITS PROCESSFIELD OF INVENTION

[0001] The present invention relates to moulds used in the production of different types of parts or objects. More specifically, it pertains to a modular mould structure comprising thin-walled sections designed for precise assembly through alignment features. The invention is particularly applicable to moulds fabricated using additive manufacturing technologies, offering a lightweight, customizable, and efficient alternative to traditional mould-making methods.BACKGROUND OF THE INVENTION

[0002] Moulding is a manufacturing process used to shape materials such as resins, waxes, polymers, elastomers, and even non-polymeric substances such as cements, plasters, and ceramics into specific forms using a mould cavity. It is employed across various industries for producing both functional components and prototypes in small to large volumes. The quality, efficiency, and reproducibility of the final product heavily depend on the design and fabrication method of the mould itself. Traditional mould fabrication methods fall broadly into two categories: high- precision subtractive manufacturing and low-skill manual techniques.

[0003] Conventional high-precision moulds are fabricated using Complex Precision Machining or Electrical Discharge Machining (EDM), which involves removing material from metal blocks to create the desired mould geometry. While these methods yield high-quality, high-output moulds, they are costly, time-intensive, and produce considerable material waste. Additionally, part designs often require modifications to suit these fabrication processes. These techniques are largely inaccessible to small-scale enterprises and individuals due to high capital investment and are unsuitable for rapid reproduction of moulds in the event of damage or demand surge.

[0004] On the other end of the spectrum, low-skilled moulding methods such as cut moulds and glove moulds rely on analog techniques where elastomers are manually poured over physical models. These methods are used by small-scale manufacturers for limited production runs but are often inconsistent, time-consuming, and constrained in their ability to replicate complex designs. The manual nature of the process also leads to variability in mould quality, and repeated reproduction of moulds using these techniques lacks both time and cost efficiency.

[0005] The prior art CN113146961A discloses a mould structure for forming an external-support airbag-type flexible clamp using 3D-printed cores combined with upper and lower die inserts and a lateral glue injection plug. However, it does not disclose a mould comprising modular thinwalled sections with peripheral alignment structures for precise assembly, nor does it include injection ports or pour holes integrated into the mould body for moulding polymer or elastomer parts, and Single or multiple clamp-type fasteners with alignment pins on the interior lateral halves for users as claimed in the present invention.

[0006] The prior art EP3241658A1 relates to thin-walled injection-moulded plastic articles designed for enhanced structural rigidity with minimal material usage. However, it does not describe a mould structure formed from assembled thin-walled sections, nor does it teach the use of alignment mechanisms, integrated injection / pour ports, or features enabling disassembly and reproduction of the mould as specified in the present invention’s independent claim.

[0007] However, fabricating this mould using CNC milling or EDM would be significantly more expensive compared to alternative moulding methods. The thin-walled structure and intricate geometries of the mould make it ill-suited for subtractive manufacturing processes, which are inherently time-consuming and material-wasteful. These methods remove material to form the final shape, resulting in excessive waste and inefficiency. Consequently, rather than reducingproduction time, cost, required skill level, and material usage, such approaches would substantially increase all these factors. Additionally, the novel thin-walled configuration of the mould limits its manufactur ability and reproducibility using traditional techniques, particularly when aiming to produce polymer moulds that are translucent or transparent — capabilities better supported by additive manufacturing technologies.OBJECTS OF THE INVENTION

[0008] The object of the present invention is to provide a modular, lightweight, and cost-effective mould structure for rapid and repeatable production of hollow or solid parts made of resins, waxes, polymers, elastomers, and similar materials — such as silicones, thermoplastics, and thermoset polymers and even non-polymeric substances such as cements, plasters, and ceramics — using additive manufacturing techniques. The invention aims to facilitate quick prototyping and scalable manufacturing by utilizing thin-walled mould sections with integrated alignment structures, injection or pour ports, and fastening mechanisms, thereby eliminating design and fabrication constraints associated with conventional moulding methods.

[0009] Said and other objects of the present disclosure will be apparent to a person skilled in the art after consideration of the following summary of subject matter as claimed, detailed description taken into consideration with accompanying drawings in which preferred embodiments of the present disclosure are illustrated.SUMMARY OF THE INVENTION

[0010] It is therefore a general aspect of the embodiments to provide a mould for producing different types of parts or objects. More specifically, the embodiments relate to a mould comprising thin-walled sections assembled via integrated alignment structures, equipped with injection ports or pour holes for introducing moulding material. The mould enhances productionflexibility, cost-efficiency, and reproducibility by enabling lightweight, easily manufactured and reassembled components — ideally suited for additive manufacturing and adaptable to both prototyping and scalable production needs. A mould for producing parts or objects is provided, comprising a main body formed from at least two sections designed to be assembled together. Each section features a thin-walled construction with a wall thickness ranging between 1.25 mm and 12 mm, enabling lightweight and material-efficient fabrication. A set of alignment structures is integrated along the periphery of the sections to ensure precise and repeatable alignment and assembly of the mould. The mould further includes one or more injection ports or pour holes, or a combination thereof, configured to introduce moulding material into the mould / cavity for forming the desired object.

[0011] According to an embodiment, the mould further comprises one or more injection ports positioned on one or more sections of the main body or formed at the interface when the sections are aligned. Each injection port includes a sealing mechanism configured to securely seal the port, thereby preventing leakage of the moulding material during or post the injection process.

[0012] According to an embodiment, the mould comprises circular ports evenly distributed around the periphery of the sections, wherein the ports function both as alignment features and fastening points for securing the mould using one or more bolts. Alternatively, the mould may employ strong magnets — such as neodymium magnets — integrated along the periphery in conjunction with alignment pegs or pins embedded within the interior of the main body, to enable secure attachment and easy disassembly. In another embodiment, the mould sections may be fastened using an external clamp-style mechanism, also used in combination with internal alignment pegs or pins on the interior lateral halves of the mould, for users who prefer a more traditional fastening mechanism and to ensure precise alignment and repeatable assembly.

[0013] According to an embodiment, the alignment structure comprises alignment pegs or alignment pins, wherein the circular ports and the alignment pegs or pins are alternately arranged along the periphery of the mould sections to ensure precise alignment and stable assembly.

[0014] According to an embodiment of the invention, the mould includes one or more pour holes or injection ports for introducing moulding material into the cavity. These openings are strategically positioned at a mould split — such as along a bilateral division in a two-part mould or at an interfacial junction in a multi-part configuration. This preferred placement facilitates efficient and uniform material distribution throughout the cavity, minimizes flow resistance and air entrapment, and enhances the overall quality and consistency of the moulded product. By aligning the material entry point with the natural separation lines of the mould, the design also simplifies manufacturing, assembly, and cleaning processes.

[0015] According to an embodiment, the pour hole has a variable diameter ranging from 1.5 mm to 100 mm, allowing the mould to accommodate different volumes of moulding material and enabling the production of both small and large-sized objects.

[0016] According to an embodiment, the pour hole incorporates a funnel-type entry point, facilitating a smoother and more controlled introduction of the moulding material into the mould cavity, and minimizing spillage or overflow during the pouring process.According to an embodiment, the mould comprises a plurality of ribs or splines distributed around its periphery, configured to reinforce the structural stability of the thin-walled sections and maintain the mould’s shape during the moulding process.

[0017] According to an embodiment, the mould comprises two or more feet designed as interlocking pieces, which can be attached to the mould to enable stable upright positioning during the moulding process or storage.

[0018] A general aspect of the embodiment is to provide fundamental method for producing a mould for forming parts or objects. It begins with structuring a main body of the mould from at least two sections, each section being formed with a thin-walled structure having a wall thickness between 1.25 mm and 12 mm. This design approach enables reduced material consumption and faster production using additive manufacturing techniques. The method also includes providing alignment structures along the periphery of the mould sections to ensure precise and repeatable assembly. Finally, it incorporates one or more injection ports or pour holes — either independently or in combination — into the mould to allow material to be injected or poured into the internal cavity formed by the joined mould sections for shaping the desired object.

[0019] According to an embodiment, specifying the configuration and function of the injection port. The injection port may be formed directly on one or more mould sections or may result from the joining of the sections at the interface. To ensure clean and efficient moulding, the method includes incorporating a sealing mechanism — such as pegs or stoppers — for each injection port. This sealing mechanism is adapted to close the port securely, preventing material leakage during or after the injection process, which is particularly useful for high-viscosity or slow-curing materials.

[0020] According to an embodiment, introducing various fastening options for assembling or disassembling the mould sections. The method involves forming circular ports evenly around the periphery of the mould sections and selecting one of the following fastening techniques: using bolts that pass through the circular ports, integrating magnets into the periphery to pair with internal alignment pins or pegs, or using an external clamp-style mechanism with interior alignment structures. This provides the user with versatile options for assembling the mould depending on production needs, precision requirements, or available tools.

[0021] According to an embodiment, arranging of the alignment structures in relation to the circular ports. It specifies that the alignment pegs or alignment pins should be incorporated as part of the mould design and arranged in an alternating pattern with the circular ports around the mould’s periphery. This dual-function arrangement ensures both accurate alignment and secure fastening, reducing misalignment risks and improving the overall structural integrity of the assembled mould.

[0022] According to an embodiment, the optimizing position of injection ports or pour holes. These ports are preferably placed at the mould split — such as a bilateral split in a two-part mould — or at the interfacial junction between multiple mould sections. Strategic placement of the entry point allows for uniform flow of the moulding material into the cavity, ensuring even distribution and minimizing defects such as air pockets, incomplete fills, or material turbulence.

[0023] According to an embodiment, integrating magnets into the mould when magnetic fastening is selected. Magnets can be embedded within the walls of the mould during the printing process by pausing fabrication at predefined layers, placing the magnets in designated cavities, and then resuming the print. Alternatively, magnets can be inserted post-printing by friction fitting them into prepared slots or securing them using adhesive bonding. This enables tool-free, fast, and repeatable mould assembly while maintaining structural strength and sealing integrity.

[0024] According to an embodiment, introducing interlocking feet that are attached to the mould body to keep it upright during the moulding process. These feet are configured to be connected to designated points on the mould sections, ensuring the mould remains in a stable, vertical orientation during pouring, injection, curing, or storage. This improves ease of use, especially when working with gravity-fed pour holes or fluid materials that require stable positioning.

[0025] The figures depict embodiments of the present subject matter for the purposes of illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the device and process illustrated herein may be employed without departing from the principles of the disclosure described herein.BRIEF DESCRIPTION OF DRAWING

[0026] Figure 1 is an illustration of different views of mould for solid part production.

[0027] Figure 2 is an illustration of different views of mould for hollow part production.

[0028] Figure 3 is exploded view of mould for hollow part production.

[0029] Figure 4 illustrate method steps for producing a mould.DETAILED DESCRIPTION

[0030] The best and other modes for carrying out the present invention are presented in terms of the embodiments, herein depicted in the drawings provided. The embodiments are described herein for illustrative purposes and are subject to many variations. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but are intended to cover the application or implementation without departing from the spirit or scope of the present invention. Further, it is to be understood that the phraseology and terminology employed herein are for the purpose of the description and should not be regarded as limiting. Any heading utilized within this description is for convenience only and has no legal or limiting effect.

[0031] The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.

[0032] The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more sub-systems or elements or structures or components preceded by "comprises... a" does not, without more constraints, preclude the existence of other, sub-systems, elements, structures, components, additional sub-systems, additional elements, additional structures or additional components. Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment.

[0033] For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as would normally occur to those skilled in the art are to be construed as being within the scope of the present invention.

[0034] It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not intended to be restrictive thereof.

[0035] Unless otherwise defined, all technical and scientific terms used herein have the same meanings as commonly understood by those skilled in the art to which this invention belongs.

[0036] Figure 1 illustrates an embodiment of a mould for producing parts or objects made of resins, waxes, polymers, elastomers, and similar materials — such as silicones, thermoplastics, and thermoset polymers and even non-polymeric substances such as cements, plasters, and ceramics,highlighting its principal structural and functional features. The central structural component of the mould is its main body (1), which is formed by two precisely matched and symmetrical halves. These halves (1) are designed to meet along a central bilateral split, enabling easy and repeatable assembly and disassembly. This split not only simplifies demoulding of the final object but also enables high-precision moulding, especially for objects with bilateral symmetry. The mould is configurable for both solid part moulding (shown in fig. 1) — where the two main halves (1) are directly bolted together — and hollow part moulding (shown in Fig. 2), where an internal chamber is first attached to one half and then enclosed by the second half before fastening.

[0037] The outer surface of the object to be moulded is digitally offset to generate the mould cavity, and the wall thickness of the resulting structure is carefully adjusted based on the object's weight. For instance, lightweight models (1-50 g) requires wall thickness range from 2-2.5 mm , moderate weight models (50g-500g) requires wall thickness range from 2.5-3.5 mm and heavier models (500-1500+ g) requires wall thickness range from 3.5-4.5+ mm with a maximum wall thickness of 12mm for larger models. Notably, the design supports fabrication of thin-walled moulds, reducing material usage by up to 80%, without compromising structural integrity. The wall thickness can be minimized to 1.5 mm for polymer-based moulds and as thin as 1.25 mm for metal moulds, making the design highly efficient, economical, and eco-friendly. This wall thickness applies to moulds made from polymers, metals, ceramics and plasters.

[0038] A critical structural and functional feature visible in Figure 1 is the presence of circular ports (2) distributed evenly along the outer periphery of each half of the mould. These circular ports (2) serve a dual function — first, they act as mechanical fastening points for nuts and bolts, which securely join the mould halves during the moulding process; second, they function as alignment features, ensuring precise and consistent registration of the mould sections. The symmetrical, alternating or alternative arrangement of these ports, pegs, or pins (2) preventsmisalignment, enhances mould stability during operation, and ensures a tight seal between the sections — crucial for both pouring and high-pressure injection moulding.

[0039] In alternative embodiments, instead of bolts, the mould can employ strong permanent magnets (such as neodymium) embedded along the periphery of the mould. In this setup, the alignment function is taken over by internal alignment pegs or pins designed into the mould's inner walls. These magnets offer an elegant, tool-free fastening solution that enables rapid and repeatable assembly and disassembly of the mould, significantly reducing the time and complexity involved in preparing and cleaning the system. This makes the magnet-based embodiment particularly well-suited for rapid prototyping, small-batch manufacturing, and environments where frequent mould changes are required.

[0040] The integration of magnets can be achieved in two distinct ways: (a) During the 3D printing process, the fabrication can be paused at predetermined layers, allowing the magnets to be inserted into specially designed slots or cavities, after which printing is resumed, thereby embedding the magnets within the mould wall; or (b) After printing, pre-designed cavities can receive magnets via friction fit or adhesive bonding, offering a flexible and repairable configuration.

[0041] Additionally, a third fastening option is available through the use of external clamp systems, which can be deployed in combination with internal alignment pegs. This method eliminates the need for embedded elements and is especially effective in workshop or experimental environments, where flexibility and accessibility are valued.

[0042] This multi-modal fastening system — bolts, magnets, or clamps — gives users the freedom to choose the best-suited assembly method based on production needs, available tools, material compatibility, and operational convenience. Collectively, these features make the mould systemhighly modular, adaptable, and user-friendly, suitable for a wide range of material types and manufacturing scales. The design ensures precision alignment, structural integrity, ease of operation, and material efficiency, which together represent the core of the technical advancement demonstrated in Figure 1.

[0043] In the disclosed mould design, circular ports (2) and alignment / registration ports or structure (3) play a dual and integrated role in ensuring mechanical fastening and precise alignment of the mould halves (1). These structure (3) are strategically distributed around the periphery of the mould sections and are crucial for achieving repeatable, accurate mould assembly — especially when the mould is reused across multiple production cycles. These structure (3) are alternately placed, with every other port serving as a registration or alignment point, eliminating the need for separate dedicated alignment pins. This alternating configuration enables the precise and repeatable joining of the mould halves (1), which is especially crucial for maintaining accuracy over multiple moulding cycles. The circular ports (2) serve a dual purpose — they act as fastener holes for mechanical joining using nuts and bolts, while also functioning as alignment structures that ensure accurate positioning of the two halves (1). When used with bolts, these dual-function ports ensure both secure clamping and high-precision alignment.

[0044] The diameter of each port is calculated based on the size of the selected fastener (e.g., M5 bolts), with an added clearance of 0.250 mm to account for smooth insertion and tolerance. This clearance is determined using a formula that multiplies the minimum resolution of the 3D printer by a factor — typically 2.5 — to accommodate variations in print accuracy. For higher- resolution printers, a reduced factor (1.5 or 2) can be used to ensure a tighter fit. The result is a set of ports (2, 3) that are engineered for both fit and functionality, adaptable to different fabrication conditions. The ports (2, 3) are spaced evenly around the mould’s edges, withadjustments made to accommodate the placement of pour holes, injection ports, and interlocking feet, ensuring a well-balanced and interference-free layout. The number of alignment holes may vary depending on the mould’s size and shape but are maintained at a minimum spacing of 2 mm to prevent structural weakness.

[0045] To further enhance the mould’s structural integrity, raised circular protrusions are optionally designed around the fastener entry points. These protrusions help distribute clamping pressure more evenly when the mould is bolted shut and allow for the incorporation of washers if required. The thickness of each protrusion is calculated by dividing the overall wall thickness of the mould by 1.6, while its diameter corresponds to the washer dimensions. This feature is particularly useful in injection moulding processes where even clamping pressure helps prevent leakage and deformation.

[0046] Complementing the circular (2) and alignment structure (3) are one or more injection ports (5), designed to deliver moulding material — such as resins, waxes, polymers, elastomers, and similar materials — such as silicones, thermoplastics, and thermoset polymers and even non- polymeric substances such as cements, plasters, and ceramics — into the internal cavity of the mould. These injection ports (5) are typically located along the split line of the mould, either integrated into one half or formed at the interface of the two halves (1) so that a complete cylindrical channel is formed only when the mould is assembled. This design minimizes the number of visible or exposed features on the final part and reduces the risk of misalignment. The injection ports (5) are equipped with sealing mechanisms (6), such as pegs or stoppers, dimensioned with tight tolerances (+ / - 0.050 mm) to ensure a secure fit and prevent material leakage or backflow, especially during the curing phase of materials with longer setting times. These sealing elements (6) can be removed or replaced as needed, depending on the application.

[0047] The mould also incorporates structural ribs or splines (7) to reinforce its thin-walled construction, particularly in regions subjected to mechanical stress or injection pressure. Pegs / Stoppers (7) are also provided for each injection port (5) in the case of polymers that have longer setting or cure times to prevent leakages. As the moulds are thin walled, they also incorporate ribs or splines (7) to increase its rigidity without substantially increasing the mould’s weight or material usage. This prevents backflow, leakage, or contamination, and ensures pressure retention during injection moulding. The injection ports (5) can be opened or closed depending on the application.

[0048] Overall, the integration of circular ports (2), alternating registration features (3), adaptable injection port sealing (5), and supporting ribs (7) results in a robust, modular, and highly efficient mould design capable of supporting both injection-based and pour-based fabrication methods across a wide range of materials including resins, waxes, polymers, elastomers, and similar materials — such as silicones, thermoplastics, and thermoset polymers and even non- polymeric substances such as cements, plasters, and ceramics. The mould incorporates two distinct types of entry configurations — pour holes and injection ports (5) — each serving different functional needs based on the viscosity and curing characteristics of the moulding material. Pour holes are generally used for gravity-fed pouring applications involving low-viscosity or liquid materials, while injection ports (5) are optimized for pressure-driven injection moulding, ideal for high-viscosity materials such as thermoplastics, thermosets, and elastomers.

[0049] Both the pour hole and injection port (5) are preferably located at the mould split, which may be a bilateral split in a two-part mould or an interfacial junction in a multi-part mould. This strategic placement enables uniform material distribution, pressure equalization, and minimized flow resistance, thereby reducing defects such as air entrapment, turbulence, and uneven filling. It also simplifies demoulding by preventing interference with the aesthetic or functional regionsof the moulded object. Alternatively, the pour hole may be positioned at the top half, bottom portion, or posterior of the mould, particularly where visual impact on the finished product is minimal.

[0050] Further, the pour hole (5) allows the user to introduce moulding material — such as resin, wax, or low-viscosity polymers — into the mould cavity. The diameter of the pour hole (5) can vary depending on the object size and filling requirements, typically ranging from 1.5 mm for small or precision objects to 100 mm or more for large-volume parts. Smaller diameters allow for controlled, clean entry points with minimal surface impact, while larger diameters facilitate faster material filling, reduce flow resistance, and ensure efficient filling of high-volume cavities. This range allows the mould to be used in both small-scale artisanal applications and larger industrial or structural parts production.

[0051] Additionally, the pole hole (5) incorporates a funnel-type entry, which widens at the top and narrows into the mould cavity. The funnel feature can be conical, bell-shaped, or tapered cylindrical, depending on the application. It guides material efficiently into the mould, and prevents spillage and material loss. It also reduces chances of air bubble entrapment at the entry.

[0052] Injection ports (5), which may be integrated into a single mould half or formed at the interface of two joined halves (1), are sealed during or after injection using pegs or stoppers (6) precisely dimensioned to the internal diameter of the port with tolerances of ±0.050 mm. These sealing elements are particularly critical when working with polymers or elastomers that have longer curing times, ensuring leak-proof performance and preventing backflow or contamination. Depending on the application, the injection ports (5) can be opened or closed selectively, offering flexibility in operation and multi-material adaptability.

[0053] Given the thin-walled nature of the mould (typically between 1.25 mm to 12 mm), ribs or splines (7) are incorporated into the design to enhance its structural rigidity. These reinforcing features are integrated into the outer surface of the mould and may be vertical, horizontal, or angled, depending on the anticipated load direction during use. The number and orientation of ribs (7) are determined by the weight of the model being moulded. For instance, models weighing 1-50 grams may have 0 to 2 bilateral ribs, those weighing 50-500 grams may include up to 3 bilateral and vertical ribs, and models above 500 grams may have up to 6 such ribs. These ribs (7) not only resist deformation, bulging, or cracking under mechanical pressure or thermal stress, but also increase the mould’s lifespan when subjected to repeated cycles of use. The ribs (7) are typically of the same thickness as the rest of the mould, spaced uniformly for balanced support and aesthetic symmetry during repeated assembly / disassembly. This enhances overall life cycle of the mould when used repeatedly.

[0054] To further improve usability and operational convenience, the mould is equipped with modular interlocking feet (4). These feet (4) are fabricated with the same wall thickness as the mould and are designed to fit into pre-formed slots or grooves located at the base or designated sides of the mould body. Depending on the design, the feet (4) may be snapped in, slid in, screwed on, or friction-fit to remain stable during moulding, curing, and storage phases. Their interlocking design ensures that the mould remains in an upright or angled orientation, especially when used with funnel-type pour holes, facilitating optimal gravity-fed material entry. Furthermore, these feet (4) are detachable, allowing for compact storage, transport, and interchangeability across different mould configurations. The ability to support the mould in a stable position during pouring or injection not only enhances process control but also reduces the likelihood of spills, misalignment, and incomplete filling.

[0055] In an embodiment of the present invention, the mould is designed to accommodate both solid (shown in Fig. 1) and hollow object fabrication (shown in Fig. 2), with flexibility in geometry and internal volume. The process begins by offsetting the outer surface or periphery of the target object to create an encompassing surface that defines the outer cavity of the mould. This offset dimension is carefully calculated, (for example a 50 gram object is being made) a minimum of 2 mm for the main mould wall + 2 mm for the protrusion for a washer or clamping area, or the thickness of the magnet insert plus 2mm for it’s encompassing surface.

[0056] For the production of completely hollow objects, the mould can be employed in a rotational moulding (roto moulding) process. In this method, a specific volume of material — such as resins, waxes, polymers, elastomers, and similar materials — such as silicones, thermoplastics, and thermoset polymers and even non-polymeric substances such as cements, plasters, and ceramics — is introduced into the cavity through the pour or injection ports (5) (as illustrated in Figure 2). Once the material is introduced, the ports (5) are sealed using precisely dimensioned stoppers or pegs to prevent leakage. The sealed mould is then mounted onto a roto moulding mechanism, which rotates the mould along multiple axes to evenly distribute the material across the interior surfaces. This allows the formation of objects with uniform wall thicknesses, ideal for hollow components such as containers, casings, or enclosed forms. The use of roto moulding with this modular mould design enables precise wall control while leveraging the advantages of additive manufacturing, such as lightweight construction and reduced material usage.

[0057] For the fabrication of partially hollow, tubular, or pipe-like structures, the mould includes an internal chamber (8) component. This chamber represents the inner surface of the hollow region of the object and is created by offsetting the relevant geometry to form a consistent wall thickness that matches the rest of the mould. The internal chamber (8) is sealed at the bottom and fitted with an interlocking or threaded peg at its posterior end to ensure secure placement withinthe mould assembly. The interlocking peg is dimensioned using the previously described clearance / tolerance formula, which involves multiplying the 3D printer’s minimum resolution by a factor of 2.5, with the option to reduce it to 2.0 or 1.5 and so on, depending on the precision and calibration of the printer used. This ensures a tight, interference -free fit between the internal chamber (8) and the outer mould halves, allowing accurate positioning and reliable structural support.

[0058] In the hollow object mould configuration (depicted in Figure 2), the mould consists of three main components: the two outer halves (1) and the internal chamber (8). This chamber is sandwiched between the two halves (1) and aligned using alignment markers (9) located at the top, ensuring accurate and repeatable positioning during assembly. These alignment markers (9) may be visual, geometric (e.g., pegs or ridges), or keyed features that eliminate misalignment during high-speed or automated assembly processes.

[0059] Furthermore, the versatility of the mould design extends to compatibility with various additive manufacturing technologies. In addition to conventional 3D printing methods such as Fused Deposition Modeling (FDM) or Stereolithography (SLA) and Selective Laser Sintering (SLS), this mould can be fabricated using more advanced, emerging methods such as Rapid Liquid Printing (RLP) and 3-Dimensional Gel Printing (3DGP). These techniques allow the production of large-scale, complex geometries in flexible or multi-material formats, further enhancing the manufactur ability and application range of the mould. This cross -compatibility with diverse fabrication methods positions the mould as a next-generation tooling solution, ideal for use in rapid prototyping, low to high volume manufacturing, and experimental research environments.

[0060] The present invention offers a highly advanced and efficient approach to mould design and fabrication, particularly through its seamless integration with modern additive manufacturing (3D printing) technologies. One of the most significant advantages lies in its compatibility with a wide range of 3D printing methods, including Stereolithography (SLA), Selective Laser Sintering (SLS), Powder Bed Fusion (PBF), PolyJet printing, and Fused Deposition Modeling (FDM), Rapid Liquid Printing (RLP) among others. This adaptability allows the mould to be produced using the most suitable technology based on the specific requirements of the end-user — whether in terms of resolution, material strength, thermal resistance, or surface finish.

[0061] When fabricated using high-resolution techniques such as SLA or SLS, the moulds often exhibit fine microscopic layer lines, which not only provide a distinctive visual texture but can also enhance the surface bonding characteristics for certain moulded materials. These microlayered surfaces may be functionally advantageous in specific applications, such as prototyping or experimental material testing.

[0062] A key advantage of this invention is its capacity for rapid design -to-production turnaround. Once the initial digital design of the mould is created and validated, it can be reproduced within hours, on demand. This rapid prototyping capability significantly reduces the lead time associated with traditional mould-making methods, which often require 2-3 weeks for tooling, machining, and finishing. In contrast, the mould described herein can be fabricated in as little as 3-4 days, and in some cases, within 24-48 hours — dramatically accelerating product development cycles.

[0063] Another benefit is the material versatility offered by the invention. The mould can be fabricated in a variety of materials — such as resins, waxes, polymers, elastomers, and similar materials — such as silicones, thermoplastics, and thermoset polymers, and even non-polymericsubstances such as cements, plasters, and ceramics and engineering plastics to metals such as aluminum or stainless steel — depending on the required durability, chemical resistance, costefficiency, and production scale. This enables the mould to cater to both small-scale, budgetconscious enterprises and larger industrial manufacturers seeking high-performance tools.

[0064] Moreover, when produced using translucent or transparent polymers, the mould allows the user to visually inspect the moulding process in real time. This transparency aids in early detection of issues such as incomplete fills, trapped air, or material separation, thus reducing wastage and improving yield quality. The visual feedback loop is particularly advantageous for training, experimentation, and sensitive processes such as casting fine-featured elastomeric parts.

[0065] From a sustainability and efficiency standpoint, the additive manufacturing process used to fabricate the mould significantly reduces material wastage — up to 80% less than traditional subtractive mould-making techniques. This not only reduces raw material consumption but also minimizes the need for post -production waste management or recycling, eliminating a separate and often costly processing stage.

[0066] Another critical advantage is the accessibility of the mould fabrication process. Unlike traditional tooling, which often requires skilled machinists, high-precision CNC equipment, and extensive hands-on experience, the present invention leverages the user-friendly nature of additive manufacturing. Individuals with basic knowledge of CAD modeling and 3D printing workflows (CAM) can independently design and print these moulds. This lowers the barrier to entry and democratizes access to high-quality tooling for hobbyists, educators, startups, and small manufacturers.

[0067] Additionally, the instant solution addresses a gap in the current technological landscape.Although additive manufacturing has seen rapid adoption in the past decade, its full potential formould design and production remains underutilized. The current invention showcases how 3D printing can be exploited not just for prototyping final parts but for building robust, reusable, and modular tooling systems.

[0068] The mould design enables quick, cost-efficient fabrication of both solid (fig. 1) and hollow parts (fig. 2) using resins, waxes, polymers, elastomers, and similar materials — such as silicones, thermoplastics, and thermoset polymers, and even non-polymeric substances such as cements, plasters, and ceramics. It supports both prototyping and mass production applications, offering the scalability and repeatability needed in commercial settings. The lightweight design, optimized through advanced wall thickness calculations and rib / spline reinforcements, reduces material costs and simplifies handling, assembly, and storage.

[0069] Figure 1 is an illustration depicting various views of the mould designed for the production of solid parts, highlighting the structural components such as the main body halves (1), circular ports (2), alignment structures (3), pour holes (5), and interlocking feet (4). Figure 2 illustrates different views of the mould adapted for hollow part production, featuring an additional internal chamber (8) positioned between the two outer mould halves (1), along with associated alignment markers (9) and injection / pour ports (5). Together, these figures demonstrate the versatility of the mould system in accommodating both solid and hollow part fabrication, using a modular, customizable, and additively manufactured design architecture.

[0070] Furthermore, Figure 3 illustrates an exploded view of a modular mould system configured for the production of hollow parts. The figure showcases the disassembled components, clearly demonstrating how each structural component is integrated to support assembly, alignment, filling, and part formation.

[0071] The figure showing internal chamber (8), which defines the hollow core of the final object. This chamber is placed between the two mould halves and mates with them securely. The Alignment markers (9) are included at the top or sides of the internal chamber or mould halves. They aid in rapid, error-free setup, especially when multiple cavities or interchangeable parts are involved. Further, Injection ports or pour holes (5) provides entry pathways for introducing moulding material. Their placement at the mould split or rear face allows efficient filling, with optional funnel-type inlets for improved flow control. Once the material is introduced, pegs or stoppers (6) are used to seal the injection or pour ports. Overall, Figure 3 highlights the modular and scalable nature of the mould design.

[0072] Lastly, Figure 4 illustrates a flow diagram (Method 400) representing the sequential steps involved in producing a mould for forming parts or objects made of wide range of materials including resins, waxes, polymers, elastomers, and similar materials — such as silicones, thermoplastics, and thermoset polymers, and even non-polymeric substances such as cements, plasters, and ceramics. The method covers key structural features and their interdependent operation, enabling a flexible and modular moulding system that supports both pouring and injection-based manufacturing techniques.

[0073] The process begins with structuring a main body (401) of the mould from at least two sections, each having a thin-walled structure, with wall thickness typically ranging from 1.25 mm to 12 mm to form the foundational shape of the mould. The thin-walled configuration reduces material consumption and fabrication time, particularly when manufactured using additive manufacturing processes.

[0074] The method continues with the formation of circular ports (402) around the periphery of the mould sections. These ports are evenly spaced and serve a dual purpose of allowingmechanical fastening and supporting alignment when used with pins. The mould sections may be assembled or disassembled using one of the following fastening mechanisms such as bolts inserted through circular ports, magnets integrated onto the periphery, used in conjunction with internal pegs or pins, or external clamp-style mechanisms combined with alignment pegs.Step 403 includes the integration of alignment structures — such as pegs or pins — along the periphery of the mould sections. These are designed to ensure precise and repeatable alignment of the mould halves. The circular ports and alignment pegs or pins are arranged alternately, which improves both alignment and mechanical engagement when using non-bolt fastening options.

[0075] Following alignment, Step 404 addresses the optional yet advantageous step of attaching interlocking feet to the mould. These feet are designed to fit into designated slots or grooves on the mould and serve to maintain the mould in an upright position during pouring or injection. This feature is particularly useful when working with funnel-type pour holes or when vertical stability is required.

[0076] Lastly, Step 405 involves incorporating one or more injection ports or pour holes (or both) into the mould. These features allow introduction of moulding material into the internal cavity. The placement of these ports is optimized, typically at a mould split or interfacial junction, to ensure uniform material flow. Each injection port may include a sealing mechanism, such as pegs or stoppers, to prevent material leakage. The pour holes or injection ports may also feature funnel - type inlets for enhanced flow dynamics.

[0077] This modular, efficient, and user-friendly process (400) is especially suited for fabrication using additive manufacturing technologies and allows the mould to be adapted for both solid and hollow part production across a wide range of polymer and elastomer formulations.Structural Components:1 Two halves / sections of the main body.2 Circular ports for Nuts and Bolts.3 Alignment / Registration port or alignment structure. 4 Interlocking Feet.5 Pour holes or Injection ports.6 Pegs / Stoppers for injection ports.7 Ribs / Splines.8 Internal Chamber. 9 Alignment Markers.

Claims

I / W e claim:

1. A mould for producing parts or objects, comprising: a main body structured from at least two sections (1) that are assembled together, wherein said sections are designed with a thin-walled structure with thickness ranging between 1.25 - 12 mm; a set of alignment structures (3) provided on a periphery of the sections of the mould for precise and repeatable alignment and assembly of the mould; and one or more injection ports or one or more pour holes (5), or combination thereof for injecting or pouring moulding material into the mould for moulding objects.

2. The mould as claimed in claim 1 , wherein the injection port (5) is placed on one or more sections (1) of the main body or formed when the sections are aligned, each injection port (5) comprises a sealing mechanism (6) for sealing the injection port (5) is adapted to be sealed using the sealing mechanism (6).

3. The mould as claimed in claim 1 comprising circular ports (2) around the periphery of the sections (1) evenly placed with respect to each other, wherein the sections (1) are fastened or disassembled by one of the following: fastening bolts passing through the circular ports (2); or magnets integrated onto the periphery of the mould, used in conjunction with alignment pegs or pins integrated on the interior of the main body; or an external clamp-style fastening mechanism, used in conjunction with alignment pegs or pins integrated on the interior of the main body.

4. The mould as claimed in claim 1, wherein the alignment structure (3) comprises alignment pegs or alignment pins, such that the circular ports (2) and the alignment pegs or the alignment pins are alternatively placed with respect to each other.

5. The mould as claimed in claim 1, comprising one or more pour holes or injection ports (5) for introducing moulding material, wherein the pour hole or injection port (5) is preferably provided at a mould split such as along a bilateral split in a two-part mould, or at an interfacial junction in a multi-part mould, at a location optimized to ensure uniform material flow.

6. The mould as claimed in claim 6, wherein a diameter of the pour hole (5) varies from 1.5mm to 100 mm for larger objects.

7. The mould as claimed in claims 3 or 4, wherein the pour hole (5) incorporates a funnel - type entry point.

8. The mould as claimed in claim 1 comprising a plurality of ribs or splines (7) distributed along the exterior of the mould to reinforce structural stability.

9. The mould as claimed in claim 1 comprising two or more feet (4) that can be attached like interlocking pieces, so that the mould is enabled to be placed upright.

10. A method (400) for producing a mould for forming parts or objects, the method (400) comprising: structuring (401) a main body of the mould from at least two sections, each section having a thin-walled structure with a wall thickness ranging between 1.25 mm andproviding a set of alignment structures (403) along the periphery of the sections to enable precise and repeatable alignment and assembly of the mould sections; and incorporating one or more injection ports or pour holes (405), or a combination thereof, into the mould to enable injection or pouring of moulding material into the internal cavity formed by the assembled sections for producing the desired object.

11. The method (400) as claimed in claim 10, wherein the injection port (405) is positioned on one or more sections of the main body of the mould or is formed at the interface when the sections are aligned, and wherein the method further comprises incorporating a sealing mechanism for each injection port, the injection port being adapted to be sealed using the sealing mechanism to prevent material leakage during or after the injection process.

12. The method (400) as claimed in claim 10, further comprising the step of forming circular ports (402) around the periphery of the mould sections, said ports being evenly spaced with respect to each other, and assembling or disassembling the mould sections by one of the following: inserting fastening bolts through the circular ports; or integrating magnets along the periphery of the mould sections and using them in conjunction with alignment pegs or pins embedded on the interior of the mould body; or applying an external clamp-style fastening mechanism together with alignment pegs or pins integrated on the interior of the main body.

13. The method (400) as claimed in claim 10, wherein the step of providing alignment structures (403) comprises forming alignment pegs or alignment pins as part of the mould design, and arranging the circular ports and the alignment pegs or alignment pins aroundthe periphery of the mould sections alternatively to each other to enable both secure fastening and precise alignment during mould assembly.

14. The method (400) as claimed in claim 10, wherein the step of forming one or more injection ports or pour holes (405) includes positioning the injection port or pour hole preferably at a mould split, such as along a bilateral split in a two-part mould or at an interfacial junction in a multi -part mould, at a location selected to enable uniform flow of moulding material into the cavity.

15. The method (400) as claimed in claim 10, wherein the magnets are integrated within walls of the main body (401) either during printing process by temporarily halting fabrication to embed the magnets at predefined locations or post-printing through friction fitting them into designated cavities and / or securing them using adhesive bonding.

16. The method (400) as claimed in claim 10, further comprising the step of attaching (404) two or more feet to the mould, wherein the feet are configured as interlocking pieces adapted to be connected to designated locations on the mould sections, thereby enabling the mould to be placed in an upright position during pouring, injecting, curing, or storage.

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