Rapid prototyping method of producing tooling for an injection mold

A method of manufacturing an article, comprising:

• forming a support block comprising a cavity defined therein, the cavity comprising a peripheral surface generally corresponding in configuration to at least one of an inner peripheral surface of the article or an outer peripheral surface of the article;
• positioning a replica of the article at least partially within the cavity such that a space is created between:
• at least one of an outer peripheral surface of the replica or an inner peripheral surface of the replica, and
• a peripheral surface of the cavity;
• injecting a resin impregnated with ceramic material into the space such that the resin substantially covers the at least one of an outer peripheral surface of the replica or an inner peripheral surface of the replica;
• allowing the resin to solidify in the space such that a rigid mold insert is formed, the rigid mold insert forming an impression of the at least one of an outer peripheral surface of the replica or an inner peripheral surface of the replica;
• removing the replica from the mold insert;
• installing the support block with the mold insert in an injection molding fixture;
• and
• injecting a material from which the article is to be formed into the injection molding fixture and into contact with the mold insert.