The two startups 2point Engineering and Injex collaborated on the development of a portable cooling vest. Using additively manufactured tooling, Injex first carried out a material test for laser welding trials and then manufactured a small series of 200 in injection molding.

Requirement: Injection molded prototypes in serial material for welding tests

The development of a portable cooling vest for the human body is being supported by 2point Engineering, a young engineering firm from central Switzerland

One of the main challenges is the development of a flexible inlet plate which could be laser welded to the waterproof, yet still breathable composite layers.

After initial trials with additively manufactured prototypes, it was necessary to quickly procure components in the production-grade material. With Injex as a manufacturing partner, the aim was to perform a series of tests using different Thermoplastic Elastomers (TPE) and Thermoplastic Polyurethanes (TPU) to identify the ideal material for small batch production.

From CAD model to pilot series in less than a week

Based on the CAD data from 2point Engineering, Injex designed an injection mold, which was then manufactured in a high-resolution additive process.

With this tool and Injex' proprietary injection molding system, a pre-series of four different TPEs could be produced in less than a week.

The customer's subsequent material tests showed that a TPU from the Desmopan family was best suited for the subsequent welding process.

Economical small-batch injection molded series with additively manufactured tooling

The additively injection molds were then used for the production of 200 parts, with costs at a fraction of aluminium or steel tooling enabling the economical feasibility of such small series production.