POPSICLES, YOUR WAY
Key Design Challenges
1. Watertight Seal
Sealing with a standard popsicle stick is key to being able to mold any kind of liquid
2. Insert Shutoff
Without creating a second part and introducing challenging-to-clean parts, the stick insert needed to be incorporated
3. Lid-Base Fit
Though non-critical for minimum viable popsicles, this fit is key to product feel and overall quality
CAD and CAM (Fusion 360)
Due to a poor seal near the insert, lots of flash was produced along the curved parting line offset. This offset should be redesigned to be less steep!
Flow Simulation
Initial shots resulted in LOTS of unpredictable air pockets. Increasing the holding time/pressure and shot volume helped solve this!
Mold Machining
Troubleshooting and Production
Lids were on the edge of requiring ejector pins -- lots of mold release and very thin form factor allowed for easy removal!
Probably didn’t need draft on mold base, molds were SUPER easy to remove due to Dynaflex flexibility
