DIY Injection Molding

Written by annat
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DIY Injection Molding
Injection moulding is often used to create plastic parts such as children's toys. (sand moulds in the snow image by Daria Miroshnikova from

Injection moulding involves a manufacturing process in which melted thermoplastics, or other hard-setting materials are injected into a mould cavity. After hardening, the mould is removed from the plastic, which has by then assumed the shape of the interior of the mould. Injection moulding with plastics requires a high energy heat source and metal moulds, both of which are not easily acquired at home. However, replacement materials, such as ballistics gel for the material and foam moulds can be used instead.

Skill level:

Things you need

  • Knife
  • Block of styrofoam (bigger than the part you want to create)
  • Ballistics gel powder
  • Bucket
  • Water
  • Duct tape
  • Funnel

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  1. 1

    Carve the foam into the shape of the desired mould. Create a hollow cavity that fits exactly like a shell over the object you want to create. The foam should be at least an inch thick to prevent breaking and leakage during moulding. Cut it into two or more separate pieces that fit together to create the mould.

  2. 2

    Duct tape all the pieces together to form a complete mould and seal all gaps. Leave one hole near the top where you will pour your ballistics gel in.

  3. 3

    Mix the ballistics gel powder with water in a bucket according to the instructions on the package and what volume of gel you will need for the project.

  4. 4

    Place the tip of your funnel in the hold in the mould and pour the ballistic gel into it until it fills the mould completely. It is OK if it overflows slightly, as the excess can be cut off later.

  5. 5

    Allow the ballistics gel to set according to the instructions it comes with.

  6. 6

    Cut the duct tape off your mould and peel off the foam.

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