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– Colorless, transparent
– Stable at high temperatures
– Resistant to cleaning products / dishwasher safe
– Compliant with safety regulations for food-grade plastics
– Strong and durable
– High-gloss surface finish
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12/7/23, 3:03 AM Injection Molded Reservoir for High-End Coffee Maker
Challenges
1. Injection Sprues
The yellow taper is just the sprue left over after injection. This needs to be broken off and trimmed
flush with the base.
Challenge: The client was worried that breaking off this piece – especially when located in a hard-to-
reach area – might actually rip a hole in the bottom of the cup. They wanted it to be reinforced on the
other side with a dome of plastic.
Solution: We advised them to keep the base area flat. This is easier to mold and will look better. But in
order to get a nice flush base, we agreed to cut off most of the sprue and then later machine it flat.
More work, but a better finish.
2. Draft Angles
The blue line shows where the cavity and core will separate – the parting line.
Challenge: As the core and cavity separate, this area will stick too much in the mold.
Solution: We put in a draft angle of 5°, enough to free the tool and still meet the functional and
aesthetic requirements.
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12/7/23, 3:03 AM Injection Molded Reservoir for High-End Coffee Maker
3. Thin Walls
There are three projecting inlet fittings at right angles to the opening direction of the mold tool.
Challenge: These features are thin-walled sections that need to be released separately from the main
cavity/core.
Solution: Hydraulic sliding cores. Here you can see where the sliders will move aside in two different
directions after injection. They create their own parting lines, but in this case these will be up against
the base of the fittings and won’t create any cosmetic problems. There are also retractable pins inside
of each core, which support the thin walls of the inlet and outlet fittings when the sliders are
withdrawn. These can then be removed separately via spring action.
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12/7/23, 3:03 AM Injection Molded Reservoir for High-End Coffee Maker
5. Manual Inserts
Three small holes needed to be molded into the cup around the circumference. These are intended
for the later mounting of a locking cap.
Challenge: The mold is becoming complicated and expensive. How to mold these without additional
hydraulic sliders?
Solution: This is an ideal place to use manual inserts which can easily be moved in and out by hand. It
takes a little longer but greatly simplifies the tool making and keeps the cost down.
6. Cooling Channels
Cooling channels are essential for maintaining a uniform wall temperature during injection, which
prevents warping.
Challenge: In this tool the channels are conventionally machined, which means they follow straight,
line-of-sight paths. This is not ideal for following the curved contours of this shape.
Solution: We created multiple cooling channels in critical areas which is acceptable for a small
prototype run. But here would be a perfect opportunity in future builds to take advantage of the
conformal cooling channels made possible with metal 3D printing.
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12/7/23, 3:03 AM Injection Molded Reservoir for High-End Coffee Maker
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