3D Printed Composites Molds
Parametric templates provide a significant efficiency boost in both design and manufacturing by enabling rapid iteration of product features. While these templates improved early-stage development, higher-volume production required a method to efficiently create identical parts. Transitioning to molded composites allowed multiple parts to be made from a single mold instead of machining each component individually. By leveraging 3D printing, I developed a workflow to generate and produce customized mold designs quickly and cost-effectively.
Project Definition
The goal was to design and fabricate 3D printed molds that could withstand the pressures and temperatures of composites manufacturing. The solution needed to balance print quality, material strength, and production efficiency while allowing for repeatable, high-quality results. Additionally, I explored bladder molding to form hollow composite structures, requiring the molds to be designed with draft angles and precise lap joint features for clean part release.
Project Design
To optimize print performance, I selected PETG filament, which offered greater strength and temperature resistance than PLA while remaining cost-effective and easy to print. Print settings, including layer height, wall thickness, and orientation, were adjusted to balance print speed, surface finish, and structural integrity. Multiple mold variations were tested, including modular segmented molds for longer tubes and intersection molds for complex geometries. Surface finishing techniques, such as high-build primer and sanding, were applied to enhance the final mold quality.
Project Delivery
Initial testing confirmed that 3D printed molds could reliably produce composite parts with excellent consistency. Straight tube molds performed well, while intersecting geometries posed challenges due to bladder inflation inconsistencies. Further development is needed to refine bladder molding techniques, particularly for complex intersections. Moving forward, I plan to explore alternative bladder materials and refine mold geometries to enhance part accuracy and reliability in production applications.
