Steve Cox of Amfori and I have collaborated on an open-source Visor Injection mould. The files are all available at the bottom of this post. Please feel free to download the files, share them around and share the results with the community, please get in touch if you make any changes, or get this to production (form at bottom).
The idea is based on the 3D printed versions that makers around the UK (and the world) are working around the clock to produce to help protect health workers. An Injection mould could potentially ramp up production, as the cycle time of an injection mould is far faster than traditional 3D printing.
Here’s is Steve’s version of the 3D printed visor, modified to meet the British Standard, by having a 10mm headband. This design uses A4 clear plastic sheets as the visor material, the spacing of the holes uses a standard hol punch to make production simple.
Below is Steve’s initial design in Fusion 360
When I saw this rendering, I got in touch with Steve and offered to build an injection mould model in Inventor, using the “Mould Design” utility that comes with Inventor. This tool has a set of standard mould bases and other tools to quickly create injection moulds and to run a basic Moldflow analysis. I have also added in a small weight part to the mould, this goes onto the bottom of the visor.
This is the mould in it’s current WIP state, as it stands I have not had the time to put in cooling channels.
I had initially thought that I would share the files on Grabcad, but due to time constraints, it was easier for me to share them from my Google Drive.
Please double check ALL sizes/dimensions BEFORE building any moulds or cutting any material, we cannot take responsibility for any mistakes. You may wish to adjust the size for shrinkage based on different materials.
Here is a link to the mould in STEP format.
Here is an Inventor 2020 pack and go of the mould.
There are some design notes to take into account:
This version of the mould is based on a DME-E mould base, 346mm x 346mm, as shown below.
The materials that have been tested are generic PP and 15% Talc filled PP, as shown below. Shrinkage applied to the mould, calculated on the material below.
Below are the Moldflow results for the Talc Filled PP, Confidence of fill is good.
Quality prediction is not as good on the Talc filled PP as the regular PP, see the image below, but for this product’s application this should not be an issue.
As mentioned above, please feel free to use the design, please let us know if you get this into production, or make any design changes.