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US 2026/0295905 A1Published application
Injection mold system, method and article
AssigneeImpossible Objects, Inc.
InventorsRobert D. Swartz, Eugene Gore, Christopher Wagner, Shay Wallace
Life of this patent
Estimating the term…
Abstract
An improved injection mold system, method, and article are disclosed, utilizing composite-based additive manufacturing (CBAM) techniques. Carbon fiber and fiberglass substrates combined with polymers, such as PEEK, produce durable molds with reduced flexing, enhanced thermal conductivity, and compatibility with higher melting point resins. The addition of boron nitride powder improves cycle times, part release, and surface finish. Molds can be fabricated rapidly at lower costs, supporting short runs, prototyping, and iterative design testing, while maintaining high-quality standards and extended mold life.
Claims12
A method of fabricating and using an injection mold, comprising:
- blending a polymer with boron nitride powder to form a composite material powder, the boron nitride powder being present in an amount effective to increase thermal conductivity and reduce flexing of the composite material;
- printing a cross-sectional layer of an injection mold onto a substrate material comprising fibers, the fibers of the substrate material being selected from the group consisting of carbon fiber and fiberglass or other appropriate substrates;
- depositing the composite material powder onto the substrate material so as to cover and adhere to all printed areas of the substrate material;
- removing powder that does not adhere to a printed layer;
- repeating the printing, depositing and removing steps until all cross-sectional layers of an injection mold have been printed, and stacking layers in registration during the repeating step to make an injection mold build block;
- heating the injection mold build block so that the composite powder softens and binds fibers of adjacent layers together in the 3D form of the injection mold;
- removing unprinted volumes of the substrate material to reveal the injection mold;
- applying a surface finishing treatment to the injection mold to enhance the surface hardness and finish of the mold structure;
- and
- using the injection mold in an injection molding apparatus to produce injection molded parts.
7 more elements
A composite injection mold, comprising:
- a mold body defining at least one mold cavity and core configured to shape an injection molded part;
- the mold body being formed from a composite material comprising:
- a polymer;
- boron nitride powder, present in an amount effective to enhance thermal conductivity and reduce flexing of the composite material;
- and
- reinforcing fibers selected from the group consisting of carbon fiber and fiberglass or other appropriated substrates;
- a surface finishing coating disposed on an exterior surface of the mold body, the surface finishing coating configured to increase surface hardness and enhance the surface finish and life;
- and
- wherein the composite injection mold is adapted for use in an injection molding apparatus to produce injection molded parts exhibiting improved cycle times, reduced mold deformation, and increased durability.
6 more elements
A method of fabricating and using an injection mold, comprising:
- printing a cross-sectional layer of an injection mold onto a substrate material comprising fibers, the fibers of the substrate material being selected from the group consisting of carbon fiber and fiberglass or other appropriate substrates;
- depositing a polymer powder onto the substrate material so as to cover and adhere to all printed areas of the substrate material;
- removing powder that does not adhere to a printed layer;
- repeating the printing, depositing and removing steps until all cross-sectional layers of an injection mold have been printed, and stacking layers in registration during the repeating step to make an injection mold build block;
- heating the injection mold build block so that the polymer powder softens and binds fibers of adjacent layers together in the 3D form of the injection mold;
- removing unprinted volumes of the substrate material to reveal the injection mold;
- applying a surface finishing treatment to the injection mold to enhance the surface hardness and finish of the mold structure;
- and
- using the injection mold in an injection molding apparatus to produce injection molded parts.
6 more elements
A composite injection mold, comprising:
- a mold body defining at least one mold cavity and core configured to shape an injection molded part;
- the mold body being formed from a composite material comprising:
- a polymer;
- and
- reinforcing fibers selected from the group consisting of carbon fiber and fiberglass or other appropriated substrates;
- a surface finishing coating disposed on an exterior surface of the mold body, the surface finishing coating configured to increase surface hardness and enhance the surface finish and life;
- and
- wherein the composite injection mold is adapted for use in an injection molding apparatus to produce injection molded parts exhibiting improved cycle times, reduced mold deformation, and increased durability.
5 more elements
Dependencies are inferred from the claim text.