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Design the shape of your mould by first considering what you would like to produce. A mould can be designed for a variety of products from toys, to plastic water bottles. After you have thought about what you want to make, make a sketch on paper. This will help give your design some form and structure before making it in CAD software. In this article we will look at how to design an injection mould using the free CAD/CAM package called Fusion 360 that has been used in numerous tutorials on our site. Once the sketch has been completed, make a part in CAD software. Use a 3D sketch to design your part. Your design must be accurate so you can create the mould profile accurately. With some CAD packages you can output the model directly to an STL for use on our 3D printer. For this example we will use Fusion 360 as it is easy to export parts directly from CAD software to STL. Remember, if you are doing this then your part is not watertight. If the STL is meant to be used for making on our 3D printer then print out at 1mm or 0. 2mm resolution and add a thick brim. The top of the mould will always be at your chosen print resolution and the bottom should be twice the size of the product you are making and should be cut edge to edge. The thickness of the part depends on how thick you want your edge, roughly twice as thick if using 1mm layers to make a toy part, and roughly twice as thick for 0.2mm layers. To make your mould we need to make a solid model in Fusion 360. This will then generate an STL that can be used on the 3D printer or sent off for injection moulding production. Once we have our model complete, we need to change some settings before exporting it. We don't want it to be solid, so from the top toolbar click "Model" then "Make Assembly from Parts". We also want to change the build size, this will depend on how big your part is and how accurate you want your mould. Once the assembly has been made, go to parts and select all of them. Export it as an STL file for use on our 3D printer or send it off to a company for injection moulding. Another option, is instead of making a solid model with a complex shape that would be difficult for us to make into a 2D shape, we could create a flat pattern shape that is easy for us to create from materials such as plywood or MDF. This is much easier to do and will also save us a huge amount of time. To do this, we need to turn the flat pattern into a parametric model that we can then manipulate in CAD software. Open the Fusion 360 part browser and find the part you would like to create. Drag it from the browser, so it appears on your screen before expanding it out. Make sure you set the "number of views" to "1". We want 1 but some CAD packages may have it as 3-6. There are many ways we can change our part, for this example we will just do three things: change the name, change the material and change rotation of angle 1. cfa1e77820
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