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Updated: 1/31/26
Initially, this project was inspired by Protolabs’ “Design Cube” demo, which illustrates a variety of injection-molding defects in a single part.
I wanted to bring a similar demonstration into the classroom so students can directly interact with the causes and solutions behind these defects. I have begun developing a series of single-part molds that each highlight a common defect. To enhance the hands-on, tactile nature of the activity, I am using Monoject 5–10 mL syringes as low-cost injectors. This keeps the demo extremely affordable and accessible for K–12 partners with limited resources. By using wax and syringes, we can melt material at crock-pot temperatures and provide a safe-to-handle injector with real tactile feedback: users can see the fill and feel the injection pressure.
Admittedly, wax is typically a eutectic fluid with very low viscosity when melted. Freeman Flakes (commonly used in lost-wax casting) offer higher-viscosity options that better represent injection molding behavior. I am also experimenting with additives to fine-tune viscosity for a closer simulation of plastic injection molding while keeping the activity safe and requiring minimal PPE.
Over time, this will expand into a full series of molds to demonstrate defects such as short shots, sink marks, warpage, flash, weld lines, and more.
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