Building a larger-capacity benchtop injection molding machine.
I built this machine to learn the mechanics and process control behind small-scale injection molding. The design combines a tall aluminum-extrusion frame, a pneumatic actuator, a heated injection assembly, and independent temperature-control zones.
One of the main goals was increasing usable shot capacity. The design expanded the shot size from approximately 56 g in the earlier reference design to about 93 g while producing roughly 1,770 lbf of injection-plunger force.
I also implemented multi-zone PID temperature control for the barrel, nozzle, and mold so the machine could maintain more consistent thermal conditions during testing.
What I worked on
- Designed and assembled the aluminum-extrusion machine frame and vertical injection mechanism.
- Integrated a pneumatic actuator and injection-plunger assembly.
- Expanded shot capacity from roughly 56 g to 93 g.
- Implemented independent PID temperature control for the barrel, nozzle, and mold.
- Integrated heaters, temperature sensors, wiring, and control hardware.
- Iterated the mechanical layout and assembly through hands-on testing and troubleshooting.
What I learned
This project gave me practical experience with the interaction between mechanical design, heat transfer, controls, pneumatics, and manufacturability. It also showed me how much machine performance depends on small details such as alignment, thermal consistency, wiring layout, and ease of adjustment.