3D printed Injection Mold


Freeform 3D printed Injection Mold

In the dynamic realm of manufacturing, staying at the forefront requires the assimilation of cutting-edge technologies. A game-changing innovation making waves in this space is the seamless integration of 3D printing and injection molding, spearheaded by the revolutionary Freeform Injection Molding (FIM). This groundbreaking process promises an astounding 85% reduction in both cost and lead time compared to conventional steel tooling methods, setting a new benchmark in efficiency and versatility.

Unveiling Freeform Injection Molding

Gone are the days of turning down projects due to unconventional material requests. The manufacturing landscape is evolving with the incorporation of rapid and cost-effective injection molding services facilitated by 3D printed tooling. This remarkable advancement is made possible by leveraging Nexa3D’s Freeform resin on existing NXE400 DLP systems, complemented by their state-of-the-art desktop injection molding system.

3D Printing and Injection Molding

Integrating 3D printing and injection molding heralds a new era in manufacturing capabilities This symbiotic relationship maximizes the advantages of both technologies, offering a harmonious blend of design freedom, material diversity, and efficiency. The incorporation of Nexa3D’s NXE 400 3D printing platform further amplifies this synergy, propelling the Freeform Injection Molding process to new heights.

Key Advantages of the Integration:

  1. Swift Prototyping and Production:

   The integration of 3D printing and injection molding ensures a swift transition from CAD file to finished part. This rapid prototyping and production cycle are invaluable for agile product development and low-volume manufacturing.

  1. Cost-Effectiveness Redefined:

 The amalgamation of these technologies results in an 85% reduction in both cost and lead time when compared to traditional steel tooling methods. This paradigm shift in cost-effectiveness makes Freeform Injection Molding an attractive choice for scenarios demanding frequent design iterations or low production volumes.

  1. Versatility Across Materials:

   Unlike many additive manufacturing processes, Freeform Injection Molding is not bound by material constraints. It seamlessly accommodates the most demanding engineering plastics and composites. This versatility becomes a game-changer for projects requiring specific resins in low quantities.

Understanding Freeform Injection Molding:

Developed by Danish company Addifab, Freeform Injection Molding accelerates the injection molding process by 3D printing soluble molds for material injection. The key features of this innovative process include:

  1. Soluble Molds:

The 3D-printed molds are soluble, allowing the creation of parts with intricate geometries previously unattainable through traditional injection molding. Once used, these molds dissolve, leaving behind meticulously molded parts.

  1. Thermal Properties:

   FIM molds act as excellent insulators, preventing heat loss from the injected material. This characteristic facilitates the rapid startup and operation of injection molding machines, bypassing lengthy temperature adjustments. Moreover, these molds exhibit high heat resistance, accommodating numerous shots and compatibility with high-heat and abrasive materials.

  1. Finish and Material Freedom:

Leveraging the extensive material selection of injection molding, Freeform Injection Molding offers unparalleled options. The high-quality finishes provided by DLP printers ensure that both mold and part finish meet the highest standards.

Nexa3D NXE 400: Elevating the Integration

The partnership harnesses the capabilities of Nexa3D’s NXE 400 3D printing platform, renowned for its size and speed, to scale up the Freeform Injection Molding process. As one of the fastest DLP printers available, the NXE 400 significantly expedites the 3D printing of molds, allowing for the production of larger parts or a higher volume of smaller parts within the same timeframe.

Future Prospects and Integration Plans:

While this integration is still in its early stages, the goal is to deliver sample parts within 3-4 weeks, with the vision of achieving 1-2 week lead times and expanding the maximum part size to cater to diverse requirements. Plans are underway to seamlessly integrate this system into the Instant Quote Tool, ensuring an even smoother experience for customers seeking streamlined manufacturing solutions.


The amalgamation of 3D printing and injection molding through Freeform Injection Molding marks a paradigm shift in manufacturing efficiency and adaptability. This transformative process, coupled with Nexa3D’s technology, redefines the landscape of low-volume injection molding, offering unprecedented cost savings, rapid prototyping, and material versatility. As the industry embraces this synergy, it underscores a commitment to pushing the boundaries of what’s achievable in modern manufacturing. The future promises a manufacturing landscape where the fusion of technologies creates a seamless and efficient production ecosystem.