Flovv-e combines 3D printing and injection molding for polyurethane production

3D printing opens up new possibilities for the manufacturing industry – also by combining it with traditional processes such as injection molding. With the Flovv-e, Neckog Industries from Texas has presented such a hybrid solution that combines both in one device.

The core component is a conventional 3D printer for ABS filament. However, the printed objects do not serve as the end result, but as molds for a directly integrated injection molding process. This enables products to be manufactured from polyurethane foam.

Polyurethane injection molding is based on the principle of the two-component process. Two liquid starting materials, which are taken from separate containers and precisely dosed, are mixed in a mixing chamber at high pressure. The resulting viscous mass is then injected into the previously printed mold and then hardens.

According to the manufacturer, this allows individually shaped foam products to be produced quickly and easily – from prototypes to small series production. One advantage over pure mold making is that the 3D-printed molds can be reused for several cycles. A color dosing system is also integrated to color the foam parts.

With their complete package of printer and injection molding system, the developers want to open up the market for cost-effective and flexible polyurethane production. Initial tests with the integrated approach have shown promising results. However, the device will initially only be available to industrial customers.