Part Design
A bottle cap design often comes in unique brand-specific designs with the added challenge of critical features around the inner part of the cap.
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Conventional tooling lacking design freedom and speed.
3D printed tooling enabling unseen speed and design freedom in the desired customer specific materials.
A classic bottle cap for your beloved Pepsi. The material used for this project is PepsiCo blue HDPE.
A bottle cap design often comes in unique brand-specific designs with the added challenge of critical features around the inner part of the cap.
After the design is completed, the digital design (STEP file) in converted into a mold design which is done by inverting the part into a cavity, in a block of material, and then adding the inlet gate(s) and initial venting.
The 2-part initial design allows for quick visual Quality Assurance.
The molds were printed at a 100μm resolution to ensure good mold quality while optimizing the build for fast production.
The parts were molded on a 7-ton Babyplast. However, the molds work hand-in-hand with any installed base molding unit.
An aluminum mold frame was used to hold the assembled mold, cycle time per part was around 5 minutes, and 1 minute cooling time was needed after each shot.
The Nexa3D alkaline solution was used for demolding these parts in just one day.
This time can be optimized through mold re-design, by removing a part of the mold before demolding, or direct removal of the part if possible.