Rapid Tooling Injection Molded Prototypes: A Case Study in Artificial Photosynthesis Technology

In this paper we will explores techniques for fabricating optical components for use in an artificial photosynthesis prototype. Specifically, methods were developed for creating rapid tooling to injection mold optics. Three mold fabrication methods were compared: CNC machining of plastic, CNC machining of aluminum, and 3D printing of plastic. For the 3D printed parts, three finishes processes were explored: hot- pressing with a steel shaft, coating with printer resin, and mechanically polishing with a scraper and buffer. Mold fabrication and finishing methods were evaluated based on speed, difficulty and quality. From this preliminary investigation, resin-coated 3D printed molds show promise for use in rapid tooling for injection molding.