In May 2024, the collaborative project 3DP-Mold was officially launched, marking the beginning of an innovative initiative aimed at transforming the polymer injection mold industry. Led by Frédéric Flahaut from Haute Ecole Arc Ingénierie, this project brings together a consortium of Swiss industrial and academic partners, all committed to tackling the challenges posed by the transition to Industry 4.0.

The primary goal of the 3DP-Mold project is to develop a novel, flexible, and cost-effective process for producing prototypes and small batches of injection-molded parts. This is achieved through the use of molds created via additive manufacturing (3D printing), thus meeting the growing demands for customization and industrial responsiveness. This project directly addresses the current limitations of traditional injection molding methods, especially for small-scale production.

The consortium includes companies from the Fribourg and Neuchâtel regions, operating in diverse sectors such as watchmaking, medtech, plastics engineering and additive manufacturing. These companies, in collaboration with Haute Ecole Arc Ingénierie, contribute valuable expertise in plastics engineering, additive manufacturing, and polymer injection.

The 3DP-Mold project leverages recent advancements in 3D printing technologies, particularly Stereolithography (SLA), Low Force Stereolithography (LFS™) and Polyjet, to design resin injection molds capable of producing complex, high-quality polymer parts. The focus is on evaluating and optimizing the various available polymers and resins, taking into account geometric, dimensional, and surface constraints.

The impact of the 3DP-Mold project is double: it aims to significantly reduce the costs and lead times associated with producing injection molds for small series, while also enhancing the competitiveness of partner companies by enabling them to acquire new skills in flexible manufacturing. The project also plans to provide protocols and data sheets to guide partner companies in the use of 3D printed molds in different industrial contexts.

The 3DP-Mold project represents a crucial step toward more agile and personalized production, in line with the demands of Industry 4.0. By combining the expertise of industrial and academic partners, this innovative project promises to redefine the standards of injection mold production, paving the way for a wide range of applications and a more sustainable and responsive industrial future.