3D Printed Polymer Mold Insert with Reinforced Thermal Manifold
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional injection molding technologies for liquid silicone rubber are expensive and labor-intensive, limiting the practicality of producing small quantities and rapid design iterations due to the need for expensive metal molds and high-pressure machines.
Innovation Solution
A one-piece injection molding tool is developed using 3D printing, incorporating an internal thermal manifold separated from the mold cavity by a heat transfer wall, reinforced with engineered supports, allowing for rapid production of small quantities of liquid silicone rubber parts without the need for expensive metal molds or high-pressure machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional metal molds and high-pressure injection molding machines are used, then manufacturing precision and reliability are improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent employs disposable or reusable 3D-printed mold inserts made from polymer materials instead of expensive, complex metal molds. These inserts are designed for limited production runs and can be easily replaced or modified, eliminating the need for costly metal machining while maintaining adequate molding precision for prototype and small-batch production.
Solution Approach 2:
The invention changes the material parameter from metal to polymer for the mold inserts, and adjusts the operating pressure parameter from high-pressure (1000+ psi) to low-pressure injection molding. This parameter change enables the use of simpler 3D-printed molds while achieving sufficient molding quality for the intended application scope.
2Reliability
If conventional metal molds are used, then manufacturing reliability is improved, but ease of manufacture and production time worsen due to expensive machining processes
Solution Approach 1:
The patent replaces traditional mechanical machining processes with additive manufacturing (3D printing) technology. This substitution enables complex mold geometries to be created directly from digital models without expensive CNC machining, reducing manufacturing time and cost while maintaining sufficient structural reliability for low-pressure injection molding applications.
Solution Approach 2:
The mold system is segmented into reusable metal mold halves and disposable/reusable polymer inserts. This segmentation allows the expensive metal components to be used only where structurally necessary, while the complex cavity features are created using cheaper 3D-printed inserts that can be manufactured quickly and modified easily.
3Ease of manufacture
If 3D printed polymer molds are used, then ease of manufacture and cost are improved, but strength and pressure resistance worsen compared to metal molds
Solution Approach 1:
The patent merges 3D-printed polymer inserts with metal mold halves to create a hybrid mold system. The polymer inserts provide complex cavity geometries and thermal management features, while the metal halves provide structural strength and pressure resistance. This combination achieves both ease of manufacture and sufficient strength for the application.
Solution Approach 2:
The invention transitions from static, high-pressure metal mold designs to dynamic, low-pressure injection molding with 3D-printed inserts. By adapting the injection process to match the capabilities of polymer-based molds (lower pressure, controlled filling), the system achieves successful molding without requiring metal-level strength, enabling rapid manufacturing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables cost-effective and timely production of small quantities of liquid silicone rubber parts with material properties suitable for mass-produced products, allowing for rapid design iterations and prototype development.
Implementation Method 1
a heating fluid manifold separated from the injection cavity by a heat transfer wall... configured to channel a thermally conductive fluid into and out of the heating fluid manifold
Data Source
AI summary
We disclose a component of an injection molding tool that includes a one piece side of a mold built up by additive manufacturing using a polymer, the side of the mold defining part of an injection cavity. The side of the mold further includes an injection port coupled to the injection cavity and a heating fluid manifold separated from the injection cavity by a heat transfer wall. The heat transfer wall is reinforced against pressure in the injection cavity by a backing of engineered supports. Inlet and outlet ports are coupled to the heating fluid manifold, configured to channel a thermally conductive fluid into and out of the heating fluid manifold. Additional additive manufacturing features and material properties are described. Complementary methods of manufacturing also are disclosed.