Multi-Material Printing Enables Low Cost Silicone Prototypes

Injection molding is widely considered the go-to method for mass production due to its efficiency and scalability. However, it’s not suitable for prototyping because the molds required for the process are expensive and time-consuming to produce. Every design modification would necessitate creating a new mold, costing thousands of dollars each time. This makes injection molding impractical for the early stages of product development, where frequent design tweaks are often necessary. To achieve a final design without incurring excessive costs, an alternative prototyping method is needed.

For those working with silicone parts, the team at OpenAeros offers a potential solution through their innovative Digital-to-Silicone (D2S) method. As showcased in their OpenRespirator project, they have developed a way to 3D print single-use molds for large silicone parts. The team initially tried 3D printing injection molds in the traditional style, but they found the process too complex and time-consuming for rapid prototyping. Their goal was to streamline the process so they could go from design to prototype in a single day instead of a week.

They discovered that printing molds using water-soluble filament significantly simplified the design process. The approach involves subtracting the desired 3D model from a solid shape in CAD software and adding holes for silicone injection. After curing, the mold can be dissolved in warm water, revealing the final silicone part. This method allows for faster iterations without the complexity and cost associated with traditional molds, making it ideal for prototyping.

The OpenAeros team took their concept even further by leveraging multi-material 3D printers to print internal structures directly within the mold. This enables additional features, such as PETG stiffening rings in the OpenRespirator project, which provide structural support for filter snap-in points on silicone mask bodies. Additionally, their video demonstrates a method for prototyping pleated filters using 3D-printed forms and silicone injection to lock everything in place. This innovative approach highlights the versatility of 3D printing beyond the usual direct printing of parts, offering significant time and cost savings in the prototyping process.

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