Injection molding tool and a method of forming an injection molding tool

A tool for injection molding, the tool comprising:

• at least one milled channel including;
• a bottom surface that is at a predefined distance from a top surface of the tool;
• and
• two opposing walls extending from the bottom surface of the channel to the top surface of the tool, a first wall of the two opposing walls being at a first angle relative to the bottom surface of the channel, and a second wall of the two opposing walls being at a second angle relative to the bottom surface of the channel,
• wherein a distance between the first wall and the second wall increases from the bottom surface of the channel to the top surface of the tool, and wherein at least one wall of the two opposing walls has a curvature.

A method of forming an injection molding tool, the method comprising:

• positioning a blank on a mount;
• securing the blank to the mount;
• milling at least one channel into the blank to form a tool body, each channel including a bottom surface that is between 0.45 and 0.55 mm from a top surface of the tool body, the at least one channel further including two opposing walls extending from the bottom surface of the channel to the top surface of the tool body, a first wall of the two opposing walls being at an angle between 50 and 60 degrees relative to the bottom surface of the channel, and a second wall of the two opposing walls being at an angle between 35 and 45 degrees relative to the bottom surface of the channel,
• wherein a distance between the first wall and the second wall increases from the bottom surface of the channel to the top surface of the tool body, the distance between the first wall and the second wall at the bottom surface is between 0.5 mm and 0.6 mm, and
• wherein at least one wall of the two opposing walls includes a first radius that is tangent to the top surface of the tool body and a second radius that is tangent to the bottom surface of the channel the first radius and the second radius are between 0.2 and 0.5 mm.