Polymer molding of undersea cables and connection using additive manufacturing

A method of molding cables and connections using additive manufacturing comprising:

• providing design requirements for a cable and/or connection, wherein said design requirements comprise form, fit, and function data for said cable and/or connection;
• wherein said form, fit, and function data includes mold envelope dimensions, mating surface information, design space size and shape limitations, raw cable dimensions, and cable layout requirements;
• taking said form, fit, and function data for said cable and/or connection and utilizing computer aided drafting to produce a three-dimensional model of a mold, wherein said mold is designed to meet said form, fit, and function data for said cable and/or connection;
• exporting said three-dimensional model into a file format that allows for three-dimensional printing and computer-aided manufacturing, wherein said file contains three-dimensional mold printing data;
• loading said file containing three-dimensional mold printing data onto a three-dimensional printer;
• printing said mold utilizing a transparent UV cured resin with a resolution down to 16 microns;
• removing said mold from said printer, cleaning support material from said mold, and checking said mold to ensure it meets said form, fit, and function data;
• verifying dimensions with a coordinate measuring machine to ensure surface finish requirements of 64 microns for a cavity and 125 microns for all other aspects of said mold, and measuring said final component to verify shrink rates were accounted for properly;
• applying a mold release composition to ensure that said urethane does not adhere to said mold and applying a heat source of 140° F. to allow for mold release composition adherence to said mold;
• molding one or more cables utilizing said mold, comprising said steps of:
• mixing an polyurethane composition;
• degassing to ˜30″ of mercury using a vacuum chamber;
• removing said preheated mold from said heat source and preparing for injection of said polyurethane once degassing is completed;
• injecting said polyurethane into said mold until said polyurethane fills a mold overflow reservoir;
• allowing said mold and said polyurethane to rest for one hour at room temperature;
• applying a heat source of 180° F. to said mold for at least 16 hours;
• removing said mold from said heat source;
• allowing said mold to cool to room temperature for one hour prior to removing molded cable and/connector assembly from mold;
• disassembling said mold and remove molded parts;
• and
• deflashing said molded cable and/connector assembly.