Two processes for building blow-moulding test tools

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HASCO Hasenclever GmbH + Co KG

Ramada Acos

Stratasys GmbH

A few helpful hints to improve the process

When using inkjet or FDM for either an insert for a mould base cavity or to make a full tool, proper clearances need to be built into the model so alignment pins or mould halves fit together. Orient the tool in the build chamber to give it the best surface finish and, depending on the goal of the prototype mould, use filler and sand the mould to achieve the desired surface. The filler will also help to seal the mould and produce a better part.

The material used to build a prototype mould should be heat-resistant enough to not deform after each cycle, and durable enough to last through as many cycles as necessary for prototyping. Inkjet and FDM 3D printing technologies each offer suitable materials.

The insulating properties of inkjet and FDM materials affect cycle time. Options to minimise this include cooling-system inserts in the 3D-printed part or through the aluminium moulding base. Simply applying compressed air can also help decrease the time required for the cooling process.

A case in point: A challenge on the shop floor

Stratasys said a container manufacturer challenged it to reduce both cost and time for the development of blow-moulded prototypes. Specifically, the goal was to prototype near-production quality parts in five days rather than seven weeks, and to do it at a lower cost.

The company selected a bottle 6 in. (152 mm) tall and 3 in. (76 mm) in diameter for the pilot project. Using Fortus PC material for the tool cavity and a machined aluminium mould base, the mould was designed and built in just two days. With only minor changes to the tool design and moulding process, the bottle was blow moulded in BP Solvay Fortiflex HP 58, a high-density polyethylene. The entire process was completed in less than five days, and the moulded prototypes met the criteria for near-production quality. Moreover, Stratasys said 3D-printed tools for one blow-moulding prototype cut a shop’s costs from $800 to $350 and time required from 10 to only two days.

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