Experiments have been performed with injection mold inserts made using solid freeform
fabrication processes in an effort to further study such applications for economic production of
small quantities of parts. Static friction coefficients were determined for HDPE and HIPS against
P-20 steel, sintered LaserForm ST-100, and stereolithography SL 5170 using the ASTM D 1894
standard. Injection mold inserts were constructed of the same three materials and were used to
inject cylindrical parts using HDPE and HIPS. Ejection forces were measured, and a model was
used to calculate ejection forces and apparent coefficients of static friction. Statistical analyses
were used to determine the effects of packing time, cooling time and packing pressure on
ejection force for the three insert types. This paper compares experimental and calculated
ejection forces, compares standard friction test results to calculated apparent coefficients of
friction, summarizes the statistical results, and comments on the feasibility of using rapid tooled
inserts for injection molding.Mechanical Engineerin
