In my previous posts, I shared the reverse engineering process of this motorcycle air intake part , a project that started several months ago with 3D scanning, CAD modeling, and prototyping.
In this post, I’m presenting the continuation of that project, focusing on the injection mold design, manufacturing, assembly, and initial production trials.
📌 Project workflow :
3D scanning → CAD modeling → 3D printing & prototype validation →
Process analysis & mold design → CNC machining → Mold assembly → Injection trials
After this stage, the mold will proceed to surface graining / texture etching and will then be ready for mass production.
Part Specifications
Component: Motorcycle air intake housing
Part weight: 428 g
Material: PP (Polypropylene)
📷 What you see in this post:
Complete mold design and mechanical layout
Initial process analysis and design considerations
CNC machining and mold assembly stages
Parts produced during initial injection trials (the shown part corresponds to the second trial shot)
📌Key Design & Engineering Notes:
✔️As visible in the images, tie-bar clearance of the injection molding machine was considered from the early design phase. To avoid interference between the mold’s hydraulic cylinders and the machine tie-bars, the mold was installed with an 8-degree rotational offset.
✔️Due to the size of the sliders and the high thermal load from molten material contact, the cooling system was designed in accordance with machining constraints and available manufacturing capabilities.
✔️The ejection system was engineered to ensure that ejector pins and runners located beneath the sliders do not interfere with slider motion, ensuring safe and repeatable operation.
✔️The ejector system features a two-piece ejector plate and utilizes the injection machine’s off-center ejector mechanism, allowing balanced force distribution and stable part ejection.
Special thanks to our client: ABZAR-SABALAN.CO
