MEAM.Design - IPD 501 - MOLD


Mold

Dates
Urethane Casting
Tu J17: Assigned

Th J19: Mold PDR

- Be prepared to discuss three complete ideas for the project.
- Compile sketches, brief size estimates, and required materials for the three designs IN A SINGLE .pdf. Email this to medesign@seas.upenn.edu by 2:00pm with the title 501-MOLD-SKETCHES-PennKey.

Tu J24: Mold Urethane CDR

- Create an exploded view of your part and mold, saved as a PDF, and email along with a pack-and-go assembly of your part and model, to medesign@seas.upenn.edu (title both the file and email as "501-MOLD-ASSEMBLY-PennKey") before class at 2:00PM.
- Be prepared to discuss your considerations for how you will make this part from urethane and how you plan to design and make an injection mold for the same part.
- Urethane casting demo

Th J26: 3D Printing

- Submit your 3D printed part as an STL to print3d@seas.upenn.edu by the end of the day. Follow the instructions for 3D printing requests as found on MEAMLabs. The recommended machine will be the ProJet6000 with the clear material and the payment source should be IPD501.

Th F09: Mold Urethane Due

- Bring your completed silicone mold and at least 2 urethane cast parts to class at 3:00PM.

Tu F14: UC Canvas Reflection Due

- Complete the Canvas reflection for Urethane Casting by the beginning of class, 3:00 PM.


Injection Molding
Th F09: Assigned

Tu F14: Injection Molding Simulation Due

- Follow the activities in the SolidWorks Plastics Guide and create a injection molding simulation. Save plots from step 13 and take screenshots from step 14 with the demo part found below.
- Create a PDF with images from your injection molding simulation and email to medesign@seas.upenn.edu (title both the file and email as "501-IM-MOLD-SIMULATION-PennKey1_PennKey2") before class at 2:00PM.
- JD Albert Guest Lecture

Th F16: IM PDR

- Be prepared to discuss your considerations for how you will design and make an injection mold for your part.
- Create an exploded view of your part and mold using Keyshot, saved as a PDF along with your results from the injection molding simulation using your part, and email along with a pack-and-go assembly of your part and model, to medesign@seas.upenn.edu (title both the file and email as "501-IM-MOLD-PDR-ASSEMBLY-PennKey1_PennKey2") before class at 2:00PM.

Tu F21: IM CDR

- Be prepared to discuss your considerations for how you will design and make an injection mold for your part.
- Create an updated exploded view of your part and mold using Keyshot, saved as a PDF along with fully defined engineering drawings using GD&T, and email along with a pack-and-go assembly of your part and model, to medesign@seas.upenn.edu (title both the file and email as "501-IM-MOLD-CDR-ASSEMBLY-PennKey1_PennKey2") before class at 2:00PM.

Th M16: IM Due

- Bring your completed molds and 10 injection molded parts to class at 3:00PM.
- Submit your Mold IM post-project evaluation on canvas.

Tu M21: IM Canvas Reflection Due

- Complete the Canvas reflection for Injection Molding by the beginning of class, 3:00 PM.


Assignment
In groups of two, design and manufacture an injection molded part that interfaces with another component.
1. Use urethane casting to prototype and evaluate the part and mold.
2. Design and machine an aluminum mold for injection molding. Injection mold at least 10 copies of your part.

Deliverables
1. At least 2 urethane cast prototypes of your part.
2. At least 10 injection molded copies of your part.
3. Engineering drawings of your part and molds.

Guidelines

  • For urethane casting we will print the tool on the ProJet 6000 HD, and you will create the mold.
  • For injection molding you will machine your entire mold.


Setup

  • Parts will be designed to fit within a 5" x 5" x 3" box.
  • Your injection molding tooling must have 1" wall thickness in X, Y, and Z.
  • Your mold will need a 1/8" deep, 1" diameter concave pocket to accommodate the outside of the nozzle. A 1" ball endmill will be provided.
  • The ID of the nozzle is 5/32".
  • The following tapered endmills are available for use in creating your molds:


Diameter Quantity Type Taper L.o.C.
3/8" 1 Square 3° 1.25"
1/4" 1 Square 1° 1.25"
3/16" 2 Square 3° 1.25"
3/16" 1 Square 2° 1.25"
1/8" 2 Square 1° 1.25"
3/32" 2 Square 1° 0.75"
1/4" 2 Ball 1° 1.25"
1/8" 2 Ball 1° 1"


Materials
Urethane Mold Making:

  • Each team will receive 1kg of BlueStar V-340 Silicone rubber with CA45 Catalyst to make a mold.
  • Each team will be allowed to print 2.0 cu. in. on either the ProJet or Objet 3D Printers
  • Acrylic/MDF from RPL.

Casting:

Injection Mold Making:

  • 5"x2" Bar stock

Injection Molding Thermoplastic:

  • Polystyrene


Resources


Some Questions

  • You created at least three versions of your part during this project: 3D printed, urethane cast, and injection molded. What are the differences between the three versions of your part and how did each influence the final design of your part? What aspects of the final part and process were not enveloped by the two prototype parts?