Benchtop Injection Molding For The Home Gamer

October 16, 2020 by Lewin Day 8 Comments

When we think injection molding, the first thing that comes to mind is highly automated production lines pumping out thousands of parts an hour. However, the very same techniques are able to be scaled down to a level accessible by the DIYer, as [The CrafsMan] demonstrates.

Using a compact, hand-actuated injection moulder, [The Crafsman] demonstrates the basic techniques behind small-scale injection molding. The PIM-Shooter Model 150A in question is designed to work with low melting point plastics like polypropylene and low density polyethylene, and can use aluminium molds which are much cheaper to make than the typical steel molds used in industry.

However, the real game changer is when [The Crafsman] busts out his silicone mold making techniques, and applies them to injection molding. By making molds out of silicone, they can be created far more cheaply and easily without the requirement of heavy CNC machinery to produce the required geometry. With the right attention to detail, it’s possible to get good results without having to invest in a custom aluminium mold at all.

Injection molding is a process that can achieve things 3D printing and other techniques simply can’t; it can even be used to produce viable lenses. Video after the break.

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Gain An Understanding Of Injection Molding’s Design Gotchas

April 19, 2020 by Donald Papp 11 Comments

When it comes to manufacturing, sheet metal and injection molding make the world go ’round. As a manufacturing method, injection molding has its own range of unique design issues and gotchas that are better to be aware of than not. To help with this awareness, [studiored] has a series of blog posts describing injection molding design issues, presented from the perspective of how to avoid and address them.

Design of screw bosses demonstrating conflict between molder’s guidelines and vendor’s recommendations. Compromising between both is a science and an art.

Because injection molding involves heat, warp is one issue to be aware of and its principles will probably be familiar to anyone with nitty-gritty experience in 3D printing. Sink marks are also an issue that comes down to differential cooling causing problems, and can ruin a smooth and glossy finish. Both of these play a role in how best to design bosses.

Minimizing and simplifying undercuts (similar to overhangs in 3D printer parlance) is a bit more in-depth, because even a single undercut means much more complex tooling for the mold. Finally, because injection molding depends on reliably molding, cooling, and ejecting parts, designing parts with draft (a slight angle to aid part removal) can be a fact of life.

[studiored] seems to have been working overtime on sharing tips for product design and manufacture on their blog, so it’s worth keeping an eye on it for more additions. We mentioned earlier that much of the manufacturing world revolves around injection molding and sheet metal, so to round out your knowledge we published a primer on everything you need to know about the art and science of bending sheet metal. With a working knowledge of the kinds of design issues that affect these two common manufacturing methods, you’ll have a solid foundation for any forays into either world.

Hackaday Podcast 038: Cyberdecks Taking Over, Resin 3D-Printing Vs FDM, Silicone Injection Molding, And The Pickle Fork Fiasco

October 4, 2019 by Mike Szczys 4 Comments

Hackaday Editors Tom Nardi and Mike Szczys comb through their favorite hacks from the past week. We loved Donald Papp’s article on considerations before making the leap from FDM 3D Printers to a resin-based process, and we solidify our thoughts on curing cement in low-gravity. Tom’s working on a Cyberdeck build, and he also found an ancient episode of an earlier and much different version of the Hackaday podcast. We’re impressed with a mostly 3D-printed useless machine, a thermal-insert press that’s also 3D-printed, and the Raspberry-Pi based Sidekick clone that popped up this week. A DIY wire-bending robot is an incredible build, as is the gorgeous wire-routing in a mechanical keyboard, and the filigree work on this playing card press. Plus you need to spend some time getting lost in this one hydrogen-line telescope project.

Take a look at the links below if you want to follow along, and as always tell us what you think about this episode in the comments!

Take a look at the links below if you want to follow along, and as always, tell us what you think about this episode in the comments!

Direct download (60 MB or so.)

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Injection Molding With A Hot Glue Gun

June 11, 2019 by Lewin Day 11 Comments

Injection molding is an industrial process used the world over for the quick and economical production of plastic parts. [Nikodem Bartnik] wanted to experiment with this at home, so whipped up some molds and got to work (Youtube link, embedded below).

[Nikodem] produced aluminium molds, using a Dremel-based CNC platform. This allowed for the design to be created in CAD software, and helps with the production of the geometry for both the part, as well as the gates and vents. Having learned about thermal issues with an early attempt, the mold was then clamped in a vice. Wood was used as an insulator to minimise heat lost to the vice.

With this setup, it was possible to mold M5 washers using hot glue, with good surface finish. Later attempts with a larger mold were unsuccessful, due to the glue cooling off before making it through the entire mold. [Nikodem] has resolved to improve his setup, and we look forward to seeing what happens next. We’ve seen others experiment in this area before, too. Video after the break.

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The Greatest Computer Ever Now Gets A New, Injection Molded Clear Case

January 21, 2019 by Brian Benchoff 55 Comments

The Macintosh SE/30 is the greatest computer ever made. It was a powerhouse when it was launched almost exactly thirty years ago today. You could stuff 128 Megabytes of RAM into it, an absolutely ludicrous amount of RAM for 1989. You could put Ethernet in it. You could turn the 1-bit black or white internal display into an 8-bit grayscale display. I think there was a Lisp card for it. These were just the contemporaneous hacks for the SE/30. Now, people are actively developing for this machine and putting Spotify on it. There’s a toolbar extension for Macs of this era that will let you connect to a WiFi network. You’ll be hard pressed to find a computer that still has a fanbase this big thirty years after release.

Now, there’s a project to create new injection molded cases for the Mac SE/30 (and the plain ‘ol SE). These cases will be clear, just like Apple prototypes of the era. It’s also one of the most difficult injection molding projects retrocomputer enthusiasts have ever taken up.

Over the years, we’ve seen some interesting projects in the way of creating new plastic cases for old computers. The most famous is perhaps the remanufacturing of Commodore 64C cases. Instead of a purely community-driven project, this was an accident of history. The story goes that one guy, [Dallas Moore], went to an auction at an injection molding factory. The owner mentioned something about an old computer, and wheels started turning in someone’s head. A Kickstarter later, and everyone who wanted a new C64 case got one. You could get one in translucent plastic to go with the retro aesthetic.

New cases for the Amiga A1200 have also been made thanks to one fan’s Solidworks skills and a Kickstarter campaign. There is, apparently, a market for remanufactured cases for retrocomputers, and it’s just barely large enough to support making new injection molding tooling.

So, about that SE/30. The folks on the 68k Macintosh Liberation Army forums are discussing the possibility of making a new case for the greatest computer Apple will ever make. The hero of this story is [maceffects] who has already modeled the back ‘bucket’ of the SE/30 and printed one out on a filament printer (check out the videos below). This was then printed in clear SLA, and the next step is crowdfunding.

While this isn’t a complete case — a front bezel would be needed to complete the case — it is an amazing example of what the retrocomputing community can do. The total cost to bring this project to fruition would be about $15,000 USD, which is well within what a crowdfunding campaign could take in. Secondary runs could include a translucent Bondi Blue polycarbonate enclosure, but that’s pure speculation from someone who knows what would be the coolest project ever.

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VCF West: Homebrew Lisp Machines And Injection Molded PDPs

August 7, 2018 by Brian Benchoff 19 Comments

Someone walks into the Vintage Computer Festival and asks, ‘what’s new?’. It’s a hilarious joke, but there is some truth to it. At this year’s Vintage Computer Festival West, the exhibit hall wasn’t just filled to the brim with ancient computers from the Before Time. There was new hardware. There was hardware that would give your Apple IIgs even more memory. There was new hardware that perfectly emulated 40-year-old functionality. There’s always something new at the Vintage Computer Festival.

Some of the more interesting projects are just coming off the assembly line. If you want a modern-day Lisp machine, that one won’t be assembled until next week, although there was a working prototype at VCF. If you want the greatest recreation of the most beautiful hardware, VCF has your back. Check out these amazing builds below.

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Injection Molding IPhone Cases From Trash

February 7, 2018 by Tom Nardi 27 Comments

We imagine you’ve heard this already, but waste plastic is a problem for the environment. We wrap nearly everything we buy, eat, or drink in plastic packaging, and yet very little of it ends up getting recycled. Worse, it doesn’t take a huge industrial process to melt down a lot of this plastic and reuse it, you can do it at home if you were so inclined. So why aren’t there more localized projects to turn all this plastic trash into usable items?

That the question that [Precious Plastic] asks, and by providing a centralized resource for individuals and communities looking to get into the plastic recycling game, they hope to put a dent in the worldwide plastic crisis. One of their latest projects is showing how plastic trash can be turned into functional iPhone cases with small-scale injection molding.

The video after the break goes into intricate detail about the process involved in creating the 3D CAD files necessary to make the injection molds. Even if you don’t plan on recycling milk jugs at home, the information and tips covered in the video are extremely helpful if you’ve ever contemplated having something injection molded. The video even demonstrates a neat feature in SolidWorks that lets you simulate how molten plastic will move through your mold to help check for problem areas.

Once you’ve designed your mold on the computer, you need to turn it into a physical object. If you’ve got a CNC capable of milling aluminum then you’re all set, but if not, you’ll need to outsource it. [Precious Plastic] found somebody to mill the molds through 3DHubs, though they mention in the video that asking around at local machine shops isn’t a bad idea either.

With the mold completed, all that’s left is to bolt the two sides together and inject the liquid plastic. Here [Precious Plastic] shows off a rather interesting approach where they attach the mold to a contraption that allows them to inject plastic with human power. Probably not something you’d want to do if you’re trying to make thousands of these cases, but it does show that you don’t necessarily need a high tech production facility to make good-looking injection molded parts.

This project reminds us of the tiles made of HDPE plastic with nothing more exotic than what you’d find in the average kitchen. Projects like these really drive home the idea that with the right hardware individuals can turn trash into usable products.

[via 3DHubs]

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