This project was done as part of a graduate-level course titled Integrated Computer-Aided Design. The elements of injection molding we were taught included drafting and analysis, venting, ribbing and design for injection molding. This project emphasized the utility of our piece. We made a mold for a Lego-themed ice tray. The mold and the final part were designed on SolidWorks. SolidWorks plastic simulation was used to ensure that the HDPE plastic would fill the mold entirely and there were no points of major sinkage. Using SolidCAM to create G-Code, the mold was cut using the Haas Mini Mill, ProtoTRAK CNC milling and manual milling. Then, the surfaces in contact were sanded and polished by hand to ensure a secure fit and limit flash. Shots were produced using a Morgan Press Molding Machine.
SolidWorks plastic flow simulation to ensure plastic reaches entire part
Draft Analysis to ensure part is properly drafted
Rendering of Mold and Part assembly