I have the following resources to prototype simple plastic parts:

• Tormach PCNC-770 using a PathPilotTM controller (Arlington VA TechShop)
• HSMXpress CAM integrated into SolidWorks 2016
• Morgan Press - 10 Ton injection molding machine (Arlington VA TechShop)
• Using ABS, PC or PVA plastic
• Using 6061-T6 Aluminum for the mold halves.

All the tutorials I have found go too far, producing interesting but complex parts involving molds with pulls and inserts that would normally be made by professional mold makers.

I need a soup to nuts mold design tutorial to make a simple part (think thimble or key fob, anything with a cavity) that takes into account:

• the mold will be fabricated using commonly available end mills (flat, ball, with/without taper) out of 6061 Aluminum
• HSMXpress CAM add-in will be used to create the Tormach CAM file (2.5D)
• shrinkage for the selected plastic (usually ABS)
• gate, feeder, sink issues relative to Morgan Molding machine (http://www.instructables.com/files/orig/FLI/4UVB/INYS3D1A/FLI4UVBINYS3D1A.jpg)

If I can find a "recipe" for creating a mold for a simple part then I can progress onto more complex parts.

If this does not exist, I am willing to put one together if I can get help with the first part: creating the mold.

Thanks, David Wurmfeld, Arlington, VA