F O R MLA B S W H ITE PA PER:

Injection Molding from

3D Printed Molds
A study of low-volume production of small plastic parts

August 25, 2016 | Formlabs and Galomb, Inc. | formlabs.com

Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . .3

Low-Volume Production Parts From 3D Printed Molds 4

Method . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Results . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Further Testing with High Temp . . . . . . . . . . . . . 8

Addressing Common Problems . . . . . . . . . . . . 10

Design Guidelines . . . . . . . . . . . . . . . . . . . . 11

Process Summary . . . . . . . . . . . . . . . . . . . . 11

Formlabs and Galomb Contact Information . . . . . . 12

FORMLABS WHITE PAPER: Injection Molding from 3D Prints 2

Fig 1 : Selection of LDPE parts produced by Galomb, Inc.

ABSTRACT

This white paper describes the production of small injection molded

thermoplastic parts that were created with 3D-printed molds produced on
a Form 2 printer and injected using a Galomb Model-B100 Injection Molder.
Two mold designs were tested in Clear Resin: one of a large butterfly and
one that produces four smaller butterflies in one shot. A third mold of a
USB device enclosure was tested in High Temp resin. These molds were
3D printed by Formlabs and the injection molded parts were produced by
Galomb Inc and Formlabs in a variety of materials.

Formlabs and Galomb, Inc.

FORMLABS WHITE PAPER: Injection Molding from 3D Prints 3

LOW-VOLUME PRODUCTION PARTS FROM 3D PRINTED MOLDS

The majority of plastic products in the world today are manufactured

by injection molding. With affordable desktop 3D printers and
injection molding machines, it is possible to create molds in-house to
produce small, functional parts in production plastics.
For low-volume production (approximately 10-100 parts), 3D-printed
molds save time and money. They also enable a more agile
manufacturing approach, allowing engineers and designers to easily
modify molds and continue to iterate on their designs with low lead
times and cost.
The Form 2 stereolithography (SLA) 3D printer produces completely
solid, smooth parts that can withstand the temperature and pressure
of desktop injection molding. 3D prints produced by SLA are
chemically bonded such that they are fully dense and isotropic,
producing functional molds at a quality not possible with FDM.
Formlabs partnered with Galomb Inc., a manufacturer of affordable
injection molding machines, to test and demonstrate the viability of
SLA 3D printed injection molds.

Fig 2: 3D printed molds in aluminium frames.

FORMLABS WHITE PAPER: Injection Molding from 3D Prints 4

METHOD

Both Clear and High Temp Resins can be used to print small
functional molds, with High Temp offering compatibility with a wider
range of thermoplastic melt temperatures. Formlabs Clear Resin was
selected because of its strength, high detail, and smooth surface
finish. Clear Resin is preferred due to its translucency as it is easy to
see when the molds have filled, but any of Formlabs Standard Resins
(Clear, White, Black, and Grey) should work, as they have similar
mechanical properties. The molds were printed with a layer height of
100 microns and took approximately 5 hours per mold. Depending on
geometry, multiple molds can be printed at once on a build platform to
increase printing efficiency.

Fig 3. Print setup in PreForm, with cavities facing upwards.

Two mold designs were printed in Clear Resin. The parts and
subsequent molds were designed to fit to the dimensions of the
Galomb machines vise clamp, the 1 in injection capacity of the
barrel, and the build volume of the Form 2. After printing, the parts
were rinsed in a bath of 90% isopropyl alcohol for 20 minutes each,
supports were removed, and support marks were sanded.
The parts were then post-cured for one hour under a 405 nm UV
bulb in order to reach full mechanical strength and stiffness. To better
understand the effect of post-curing parts, see Formlabs white paper
on UV post-curing.

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Fig 4. 3D printed molds in aluminum frames and injection molded parts.

The first mold was a large Formlabs butterfly logo and the second
was four small Formlabs butterfly logos. Both molds had a cavity, a
narrow gate, and a sprue to the injection point, and were designed
in Solidworks. The molds were inserted into aluminium frames to
provide support against the downward pressure and heat of the
injection nozzle. Aluminum frames may also prevent the mold from
warping after repeated usage. The frames pictured in Figures 2
and 4 were custom machined by Whittaker Engineering in Scotland,
but standard aluminium frames are readily available from injection
molder manufacturers.
Plastic pellets are available from online retailers or school supply
companies, such as IASCO-TESCO. To create a variety of colors, the
molten plastic was pre-mixed with powdered colorants before injection.
Using the benchtop Model-B100 Injection Molder, Galomb tested the
printed molds with 25 shots of LDPE. LDPE melts at approximately
325 F (163 C) and was chosen for its low melt temperature. It should
be noted that Formlabs Clear Resin has a heat deflection temperature
(HDT) @ 0.45MPa of 73.1 C after post-cure (see the material data
sheet). HDT is an indication of the materials thermal properties, but
does not rule it out for this application, even though LDPE has a higher
melt temperature. Whether or not your 3D-printed mold will withstand
the injection molding process depends on the melt temperature of the
injection material, part geometry, and the cooling and cycle time used.

FORMLABS WHITE PAPER: Injection Molding from 3D Prints 6

CLEAR RESIN RESULTS

After 25 shots of LDPE, there was no noticeable surface deterioration

(chips, cracks, or scratches) of the molds. LDPE did not tend to adhere
to the resin molds in testing, but other plastics may require an
application of mold release agent to help with the extraction of the part.
Adhesion of the part to the mold can cause deterioration of the mold
during extraction. Mold release is widely available, and silicone mold
release is compatible with Formlabs Standard and High Temp Resins.
Cycle time for each shot was approximately three minutes. This
process was accelerated by applying compressed air to cool the
mold. Cyclic injection in molds printed on the Form 2 causes the mold
to heat up. To counteract this, cooling time with the mold open should
be increased between cycles. While the mold may not deform, too
much residual heat will reduce molding success if the mold is opened
too early. Galomb also improved molding success by etching in
shallow (0.05 mm deep) air vents (not pictured) leading from the edge
of the cavity to the edge of the mold so that air did not get trapped
inside the cavity during injection.
Some of the shots exhibited flash at the split line, due to warpage
of the resin mold during the cooling phase after multiple shots.
Increasing clamping force in the vise can help mitigate flash, as can
polishing the molds split plane to give it as flat a surface as possible.
Galomb proposed including channels in the mold design to embed
metal tubes and filling these with aluminium-filled epoxy as a strategy
to reinforce the mold, reduce warpage, and improve cooling time.

Fig 5. An assortment of injection molded parts made with 3D printed molds.

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FURTHER TESTING WITH HIGH TEMP RESIN

Clear Resin molds were tested with success using LDPE, which has
a relatively low melt temperature. Higher melt temperature plastics
can cause thermal shock in Clear Resin prints, which appears as a
fractured mold surface.

Clear resin molds experience thermal shock when exposed to higher

temperature molten plastic.

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 Formlabs printed a mold of a USB device enclosure in High Temp Resin
to test benchtop injection molding with a wider range of plastics.

SLA Printed Mold Plastic Compatibility

Melt Temperature High Temp Clear
Plastic
(Source: Plastic Troubleshooter) (HDT @ 0.45 MPa = 289 C) (HDT @ 0.45 Mpa = 73.1 C)

LDPE 163 C
PP 177 C

TPE 177 C

PLA 180 C

ABS 204 C

HDPE 204 C

EVA 204 C

PS 226 C

The High Temp Resin molds showed no temperature degradation on the mold
surface for any of the plastic tested.

High Temp and Standard are the resins best-suited for moldmaking. Of Formlabs
Resins, High Temp has the highest HDT @ 0.45MPa and low thermal expansion.
It is also the stiffest material, with high tensile modulus.

The relatively high stiffness of High Temp Resin means that the mold
will not deform when removing the part. This makes the use of
mold release especially important to remove parts shot in rigid plastics
such as polystyrene.

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ADDRESSING COMMON PROBLEMS

Flash caused by overfilling a mold.

Flash occurs when the injected plastic is forced out between the two
halves of the mold. This can happen when a mold is overfilled, or if the
parting plane is not perfectly flat. Adding thin exit runners to a mold can
help mitigate flash from overpressure inside the mold, help with part
removal, and fix air traps that would cause bubbles in the molded part.
While not pictured, printed molds were tested without an aluminium
frame. The disadvantage to this approach is that these parts use more
material, which increases print cost and time, and molds may be more
prone to warping. With this method a steel washer placed between the
printed mold and the nozzle of the injection molding machine protects
the print from direct contact and helps to distribute forces. Additionally,
pre-packing the injection molding machines barrel by compressing it
against a metal block helps ensure that that there are no air pockets to
disrupt the flow of plastic.
Print lines are visible on some of the parts; this could be reduced by
printing the mold with a smaller layer height. The molds used in this
study were printed with a layer height of 100 microns, but 50 or 25
microns could also be used. This will improve the surface finish of the
mold, but increase print time and decrease tank lifespan.

Final USB enclosure created with High Temp mold.

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 DESIGN GUIDELINES

When designing your mold, consider what will print

successfully, as well as what will mold successfully.

Adding one to three degrees of draft on surfaces Embossed and engraved details should be offset
perpendicular to the direction of pull will allow the part from the surface by at least 1 mm.
to be removed more easily and minimize degradation Split plane surfaces can be polished with fine-grit
of the mold. Fillets should be applied to interior edges sandpaper to reduce flash.
to reduce warpage from internal plastic stress and
aid part removal. If designing for an aluminium frame, add .125 mm
of extra thickness to the back of the mold plates
to account for compression forces and to ensure
90 angle a complete seal.
Make sure to orient the mold halves in PreForm so
that the cavity faces up. This will prevent having
support marks inside the cavity and make post-print
2 draft processing easier.

Optimal Condition,
2 draft and fillet

PROCESS SUMMARY

STEP 1 STEP 2 STEP 3

Design the part in CAD. Design the mold in CAD. 3D print the molds on the Form 2.

STEP 4 STEP 5 STEP 6

Remove support material Inject the mold with plastic. Remove the part from the mold.
from the molds.

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Contact Formlabs to learn how desktop
SLA can work for your project.
Sales Inquiries EU Sales Inquiries China Sales Inquiries
[email protected] [email protected] [email protected]
617-702-8476 +44 1765 694053 +86 4006-029-015
formlabs.com formlabs.com elite-robot.com

Contact Galomb, Inc. to learn more

about benchtop injection molding.
Galomb Injection Molder
[email protected]
610-434-3283
injectionmolder.net

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