WO2026006288A1 - Système de moule d'injection, procédé et article - Google Patents

Système de moule d'injection, procédé et article

Info

Publication number
WO2026006288A1
WO2026006288A1 PCT/US2025/035014 US2025035014W WO2026006288A1 WO 2026006288 A1 WO2026006288 A1 WO 2026006288A1 US 2025035014 W US2025035014 W US 2025035014W WO 2026006288 A1 WO2026006288 A1 WO 2026006288A1
Authority
WO
WIPO (PCT)
Prior art keywords
mold
injection mold
injection
composite
boron nitride
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/US2025/035014
Other languages
English (en)
Inventor
Robert D. SWARTZ
Eugene GORE
Christopher Wagner
Shay Wallace
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Impossible Objects Inc
Original Assignee
Impossible Objects Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Impossible Objects Inc filed Critical Impossible Objects Inc
Publication of WO2026006288A1 publication Critical patent/WO2026006288A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/38—Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
    • B29C33/3807—Resin-bonded materials, e.g. inorganic particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/26—Moulds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2071/00—Use of polyethers, e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2909/00—Use of inorganic materials not provided for in groups B29K2803/00 - B29K2807/00, as mould material
    • B29K2909/02—Ceramics
    • B29K2909/04—Carbides; Nitrides

Definitions

  • Injection molding is a well-established manufacturing process that has facilitated the production of a wide range of parts used in numerous applications. Over time, this process has been refined to achieve high-volume production with relatively low per- unit costs.
  • Traditional mold-making techniques have evolved over decades and are widely recognized for their reliability. Nonetheless, these techniques often involve substantial design efforts, complex machining, and considerable investment in specialized tooling, which can reduce adaptability and responsiveness in modern manufacturing settings.
  • parts of the injection molding process are time-consuming and expensive. However, it has the advantage of mass-producing parts relatively quickly at low cost. Molding making is expensive, where molds can take months or even years to produce and can cost hundreds of thousands of dollars and require skilled engineers to design and make. Mold design is difficult and unpredictable and often when a mold is first put into a press, it does not work properly and has to be reworked. Beyond that, molds often break and require costly and time-consuming repair, which disrupts production and schedules.
  • Additive manufacturing techniques have also been used including stereolithography and selective laser sintering, among others, to make injection molding tools. These methods have a number of problems including short mold life, low draft angles, and flexure of the mold, making part release more difficult, not to mention low melting point mold materials.
  • the present invention provides a mold fabrication system that reduces production time from weeks to hours, lowers costs, and enables rapid prototyping and backup molds, and short production runs.
  • the present invention includes an injection mold manufactured from layers of a composite material to form a mold structure.
  • the composite material comprises a high performance polymer and boron nitride powder — where the boron nitride powder may be hexagonal and is present in an amount ranging from about 10 wt% to about 20 wt% to enhance thermal conductivity and reduce flexing — as well as either carbon fiber or fiberglass. Mold construction without boron nitride is also possible and yields acceptable results.
  • the present invention includes a method for fabricating an injection mold comprising blending a high performance polymer with boron nitride powder to form a composite powder, wherein the boron nitride powder is present in an effective amount to increase thermal conductivity and reduce flexing, and where this combination powder is use as an input to a CBAM process.
  • the method further comprises incorporating a substrate for the CBAM process that uses reinforcing fibers chosen from carbon fiber and fiberglass or other substrates.
  • the method optionally includes applying a surface finishing treatment by techniques such as electroless plating, electroplating, or continuous vapor deposition, and employing the mold structure in an injection molding apparatus to produce injection molded parts with improved cycle times, superior surface finish, and enhanced durability.
  • the high performance polymer may be polyether ether ketone (PEEK).
  • the disclosure includes a composite injection mold comprising a mold body that defines at least one mold cavity and core for shaping an injection molded part.
  • the mold body is formed from a composite material that includes a high performance polymer, boron nitride powder — present in an amount effective to enhance thermal conductivity and reduce flexing — and may also include reinforcing fibers selected from carbon fiber and fiberglass.
  • a surface finishing coating is optionally disposed on an exterior surface of the mold body to increase surface hardness and enhance the overall finish.
  • the composite injection mold is adapted for use in an injection molding apparatus to produce parts exhibiting improved cycle times, reduced mold deformation, and increased durability.
  • FIG. 1 illustrates a mechanical drawing of a mold cavity and core within an injection mold system in accordance with a preferred embodiment of the present invention.
  • FIG. 2 is a perspective view illustrating three mold components of an injection mold structure in accordance with a preferred embodiment of the present invention.
  • FIG. 3 is a mechanical drawing illustrating an injection mold fabrication system incorporating a composite-based additive manufacturing mold in accordance with a preferred embodiment of the present invention.
  • FIG. 4 illustrates a mechanical drawing of top and bottom mold cavity and core configurations for shaping injection molded parts in accordance with a preferred embodiment of the present invention.
  • FIG. 5 illustrates a perspective view of a mold structure fabricated using the composite-based additive manufacturing process in accordance with a preferred embodiment of the present invention.
  • FIG. 6 illustrates an alternative perspective view of the mold structure of FIG. 5.
  • FIG. 7 provides a front elevation view of the mold structure of FIG. 5 annotated dimensions A and B for reference.
  • FIG. 8 shows a side elevation view of the mold structure of FIG. 5 highlighting the thickness C and profile of the mold.
  • FIG. 9 illustrates a perspective view of a mold structure fabricated using the composite-based additive manufacturing process in accordance with a preferred embodiment of the present invention.
  • FIG. 10 illustrates an alternative perspective view of the mold structure of FIG. 9.
  • FIG. 11 provides a front elevation view of the mold structure of FIG. 9 annotated dimensions D and E for reference.
  • FIG. 12 shows a side elevation view of the mold structure of FIG. 9 highlighting the thickness F and profile of the mold.
  • FIG. 13 illustrates a perspective view of a mold structure fabricated using the composite-based additive manufacturing process in accordance with a preferred embodiment of the present invention.
  • FIG. 14 illustrates an alternative perspective view of the mold structure of FIG. 13.
  • FIG. 15 provides a front elevation view of the mold structure of FIG. 13 annotated dimensions G and H for reference.
  • CBAM Composite Based Additive Manufacturing
  • boron nitride powder also improves the quality of the mold; by adding boron nitride powder to the polymer powder used in the CBAM process, the heat conductivity of the powder improves, which reduces the increased temperature of the mold. This is advantageous for molding as it reduces cycle time and thus reduces costs.
  • Use of boron nitride also lubricates the mold, making it easier to remove parts, and gives an improved surface finish due to material hardness and reduces the flex in the mold.
  • the boron nitride powder is mixed with, for example, the PEEK polymer before it is used in the printer and before the sheet or web is powdered.
  • boron nitrate is hexagonal.
  • boron nitride enhancement produces a mold which compresses and flexes less. This allows for steeper draft angles, which is desirable and not available in other additive methods.
  • the amount of boron nitride can be varied and composites with 15wt% of the PEEK replaced with boron nitride were found to possess an average of elastic modulus of 15.6 GPa, a failure stress of 227 MPa, and a thermal conductivity of 0.88 W/m-K. This demonstrates that there can be an increase in mechanical properties when compared to typical carbon fiber/PEEK despite including a lubricious material in the composite, accompanied by an over doubling of thermal conductivity. These numbers are increased from the failure stress of carbon fiber PEEK which is in the range of 180 MPa.
  • the tools can be plated using electroplating or electroless plating, or continuous vapor deposition, to make any even harder surface for longer mold life.
  • Another advantage, in addition to speed and time, is that actual performance of the mold can be tested and questions about fill, cycle time parting lines and other typical issues can be understood and corrected in a production steel tool.
  • the invention provides a novel approach to fabricating injection molds made using composite-based additive manufacturing (CBAM) techniques, which significantly reduce production time and costs while improving mold performance and durability.
  • CBAM composite-based additive manufacturing
  • the injection mold system 100 includes an additive manufactured mold configured to receive an injection of plastic to be made into a part shaped according to the mold.
  • the mold itself is formed as deposited layers of a composite material to form a mold structure 200, in accordance with CBAM techniques described in the above-mentioned patents (as modified herein).
  • the composite material comprises a high-performance polymer, such as polyether ether ketone (PEEK), and boron nitride powder, which may be hexagonal boron nitride.
  • the boron nitride powder was preferably present during the powdering phase of CBAM manufacturing in an amount ranging from about 10 wt% to about 20 wt% to enhance thermal conductivity and reduce flexing of the mold structure.
  • Reinforcing fibers such as carbon fiber or fiberglass, were incorporated into the composite material (via their presence on CBAM substrate sheets or webs) to further improve strength and dimensional stability.
  • post-processing may be used to apply a surface finishing treatment.
  • the surface finishing treatment may include electroplating, electroless plating, or continuous vapor deposition, which increases surface hardness, enhances the finish, and extends the mold's operational life. These treatments also enable the mold to produce injection molded parts with steeper draft angles and improved part release.
  • a ceramic based finish e.g. CERAKOTE® may also be used.
  • a preferred composite injection mold as shown by way of example in FIG. 4, comprises a top mold body 401 and bottom mold body 402 which define at least one mold cavity and core configured to shape an injection molded part.
  • the mold body is formed from the composite material described above, which provides enhanced thermal conductivity, reduced flexing, and increased durability.
  • the mold body further includes a surface finishing coating disposed on its exterior surface to improve surface hardness and finish.
  • FIGS. 5-8 depict perspective views of a mold structure 500 fabricated using the composite-based additive manufacturing process in accordance with a preferred embodiment of the present invention.
  • FIG. 6 illustrates an alternative perspective view of the mold structure of FIG. 5.
  • FIG. 7 provides a front elevation view of the mold structure of FIG. 5 annotated dimensions A and B for reference, and
  • FIG. 8 shows a side elevation view of the mold structure of FIG. 5 highlighting the thickness C and profile of the mold.
  • FIGS. 9-12 depict perspective views of a mold structure 600 fabricated using the composite-based additive manufacturing process in accordance with a preferred embodiment of the present invention.
  • FIG. 10 illustrates an alternative perspective view of the mold structure of FIG. 9.
  • FIG. 1 1 provides a front elevation view of the mold structure of FIG. 9 annotated dimensions D and E for reference, and
  • FIG. 12 shows a side elevation view of the mold structure of FIG. 9 highlighting the thickness F and profile of the mold.
  • FIGS. 13-16 depict perspective views of a mold structure 700 fabricated using the composite-based additive manufacturing process in accordance with a preferred embodiment of the present invention.
  • FIG. 14 illustrates an alternative perspective view of the mold structure of FIG. 13.
  • FIG. 15 provides a front elevation view of the mold structure of FIG. 13 annotated dimensions G and H for reference, and
  • FIG. 16 shows a side elevation view of the mold structure of FIG. 13 highlighting the thickness I and profile of the mold.
  • the composite injection molds shown, by way of example in FIGS. 5-16, are adapted for use in an injection molding apparatus of the present invention to produce parts exhibiting improved cycle times, superior surface finish, and reduced mold deformation.
  • the mold's compatibility with higher melting point resins and its ability to maintain dimensional stability under high-pressure conditions make it suitable for a wide range of applications, including automotive components, consumer goods, and rapid prototyping.
  • the invention addresses longstanding challenges in mold fabrication, including extended lead times, high costs, and unpredictable performance.
  • CBAM techniques and incorporating boron nitride powder and reinforcing fibers, the system achieves rapid mold production — often within hours to days — at significantly lower costs compared to conventional ONG machining or other additive manufacturing methods.
  • Variations of the invention may include adjusting the composition of the composite material to suit specific applications. For example, the amount of boron nitride powder may be varied to optimize thermal conductivity and mechanical properties. Additionally, the reinforcing fibers may be selected based on the desired strength and flexibility of the mold structure.
  • the invention also supports iterative design testing and short production runs, enabling manufacturers to quickly adapt to changing requirements. Multiple molds can be fabricated at low cost, allowing for design modifications without significant expense or delay.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)

Abstract

L'invention concerne un système, un procédé et un article de moule d'injection améliorés utilisant des techniques de fabrication additive à base de composite (CBAM). Des substrats de fibres de carbone et de fibres de verre combinés à des polymères, tels que le PEEK, produisent des moules durables avec une flexion réduite, une conductivité thermique améliorée et une compatibilité avec des résines à point de fusion plus élevé. L'ajout de poudre de nitrure de bore améliore les temps de cycle, la libération de pièce et la finition de surface. Les moules peuvent être fabriqués rapidement à des coûts inférieurs, en prenant en charge des essais courts, un prototypage et un test de conception itératif, tout en maintenant des normes de haute qualité et une durée de vie de moule étendue.
PCT/US2025/035014 2024-06-24 2025-06-24 Système de moule d'injection, procédé et article Pending WO2026006288A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US202463663411P 2024-06-24 2024-06-24
US63/663,411 2024-06-24

Publications (1)

Publication Number Publication Date
WO2026006288A1 true WO2026006288A1 (fr) 2026-01-02

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ID=98222775

Family Applications (1)

Application Number Title Priority Date Filing Date
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Country Status (1)

Country Link
WO (1) WO2026006288A1 (fr)

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20160145411A1 (en) * 2013-06-19 2016-05-26 3M Innovative Properties Company Component part produced from a polymer/boron nitride compound; polymer/boron nitride compound for producing such a component part and use thereof
WO2018222475A1 (fr) * 2017-06-02 2018-12-06 3M Innovative Properties Company Inserts de moule imprimés en 3d pour moules à injection
US20230191543A1 (en) * 2021-07-22 2023-06-22 Scofast Llc System and method to perform dissimilar operations in a single machine
US20230391976A1 (en) * 2021-01-04 2023-12-07 Impossible Objects, Inc. Recycled Polymers for 3D Printing

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20160145411A1 (en) * 2013-06-19 2016-05-26 3M Innovative Properties Company Component part produced from a polymer/boron nitride compound; polymer/boron nitride compound for producing such a component part and use thereof
WO2018222475A1 (fr) * 2017-06-02 2018-12-06 3M Innovative Properties Company Inserts de moule imprimés en 3d pour moules à injection
US20230391976A1 (en) * 2021-01-04 2023-12-07 Impossible Objects, Inc. Recycled Polymers for 3D Printing
US20230191543A1 (en) * 2021-07-22 2023-06-22 Scofast Llc System and method to perform dissimilar operations in a single machine

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