Laser Welding of Injection Molded Prototypes from AM-Tool

Within a few days from the CAD-model to real injection molded parts. Prototypes made from production grade materials. Economical production of small-batch injection molding runs. All with the help of additive manufactured injection molding tools and the agile production process of Injex.

Requirement: Injection molded prototypes from production-grade materials for laser welding

The young engineering firm 2point engineering GmbH from central Switzerland supported one of its customers in the development of a portable cooling vest for the human body.

One of the main challenges was the development of a flexible inlet plate which could be laser welded to the waterproof yet still breathable composite layers.

After the initial trials with additively manufactured prototypes, it was necessary to quickly procure components in the production-grade material. At that time, Injex was involved as a manufacturing partner. The aim was a series of tests of different TPEs to identify the optimal material for the subsequent small batch production.

From CAD-model to an injection molded preseries in less than a week

Based on the CAD data provided by the customer, Injex designed an injection molding tool, which was subsequently manufactured in a high-resolution, additive process.

With this tool and Injex's proprietary injection molding system, a pre-series of four different TPEs could be produced in less than a week.

The customer's subsequent material tests have shown that a Desmopan TPU is best suited for the subsequent welding process.

Economical small-batch injection molding run with additve manufactured injection molding tool

The additively manufactured injection molding tool could also be used for the production of a small series of 200 pieces. The cost was a fraction of a steel or aluminum tool, making injection molding economical feasible for such a small batch. 

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