How to 3D print Mold Inserts with the Axtra3D Lumia X1 SLA Printer

The Challenges of Traditional Tooling

Traditional injection mold tooling comes with several drawbacks that slow down innovation and increase costs:

High material costs – Tool steel and aluminum are expensive, making small production runs costly.

Long lead times – Machining and tool preparation can take weeks.

Design limitations – Complex geometries are often impossible to machine.

Waste and inefficiency – Iterative design changes require new tools, adding to expenses.

These factors often force manufacturers to compromise on design and slow down the production cycle.

A Faster, Cost-Effective Alternative: 3D-Printed Mold Inserts

Axtra3D has developed a better way to produce mold inserts using its Lumia X1 SLA printer with Ultracur3D® RG 3280, a ceramic-loaded polymer. This process enables:

Rapid prototyping – Go from design to injected part in a single day.

Reduced costs – Significantly lower material and machining expenses.

More design freedom – Achieve complex geometries without traditional machining limitations.

Production-level quality – Inserts withstand high injection pressures and deliver precise results.

Key Benefits of Axtra3D Mold Inserts

The Lumia X1 printer, combined with Ultracur3D® RG 3280, delivers exceptional performance:

High stiffness and temperature resistance – Mold inserts hold up under pressure, maintaining accuracy and preventing deformation.

Superior accuracy – Inserts are flat within 20 microns, ensuring crisp detail and consistency.

Minimal post-processing – The glossy mating surfaces require only washing and curing before use.

Longer-lasting molds – Depending on the material, inserts can handle 300 to 3,000 injection cycles before showing wear.

Versatile material compatibility – Successfully used with polycarbonate, polypropylene, TPE, and TPU.

Real-World Example:

A case study demonstrates the efficiency of this method:

Tooling design time: 45 minutes

Printing time: 54 minutes

Post-processing and curing: 60 minutes

Machining for mold fit: 120 minutes

Total time: Less than 5 hours

Injection results: 30+ polypropylene parts for review, with a later iteration producing 300 polycarbonate/polypropylene parts

Total mold insert cost: Under $100

A Game-Changer for Low-Volume and Bridge Manufacturing

With the ability to quickly produce high-quality mold inserts at a fraction of the cost, Axtra3D’s technology is an ideal solution for:

Small-batch production – Avoid the expense of full-scale tooling for limited runs.

Bridge manufacturing – Maintain production while transitioning to mass manufacturing.

Rapid design iteration – Test multiple design versions without waiting for new machined tools.

Get Started with Axtra3D

If you're looking to streamline your injection molding process and cut costs without sacrificing quality, the Axtra3D Lumia X1 SLA printer is the solution you need.

Ready to revolutionize your molding process? Contact us today to learn how Axtra3D can help your business stay ahead!