Freeform Injection Molding
Wilson/DeMarini Baseball Bat

Wilson/DeMarini Baseball Bat

The challenge: Slow production development of mold tool.
The solution: Increased product development by 88% with 3D printed tooling.

The part is a handle in a baseball bat.
The material are a Wilson/DeMarini proprietary composite.

Part Design(s)
Part Design(s)
Close up of the 3D render of the baseball bat.
The handle was designed specifically for a Wilson Sporting Goods/DeMarini baseball bat. The challenges often surround the combination of strength, light-weighting and customized design.

We preferably work with STEP files as input from our clients.
30 minutes
Mold Design(s)
3D render of molding tool for Wilson sporting goods.
Next step is converting the STEP file into a mold design which is done by inverting the part into a cavity, in a block of material, and then adding the inlet gate(s) and initial venting.

The 2-part initial design allows for quick visual Quality Assurance.
60 minutes
Printed Tooling
3D printed molding tool for Wilson sporting goods.
The first molds were printed in a 76.5µm resolution. The prioritization was speed.
5 minutes
Freeform Injection Molding (FIM)
Injected 3D printed mold for Wilson sporting goods.
The parts were molded on a 418-ton injection molding machine at Wilson Sporting Goods. However, the molds work hand-in-hand with any installed base molding unit.

An aluminum mold frame was used to hold the assembled mold, cycle time per part was around 5 minutes, and 1 minute cooling time was needed after each shot.
5 minutes
Glen Mason removing the injection molded part from the 3d printed tool.
In this specific case the split mold allowed for manual demolding. Meaning no part of the mold had to get dissolved, as the part could be pulled off.
Total time to 1st injection molded part:
100 minutes
A set of baseball bats made with 3D printed tooling.

- The mold design is an easy process; similar to building a mold box around the design, and then make it a cavity.

- The Wilson Sporting Goods/DeMarini proprietary composite materials filled the molds nicely in the first test rounds.

- Datasheet materials were used for molding data, settings, pressure, temperatures, and more.

- Early hands-on testing for i.e. assembly and performance using first-out-of-tool parts is valuable for most team members: materials, design, process, regulatory, and if you need to make another round of iterations, you can do these the same day.


One of the Injection Molding machines at Addifab.
Accelerated development with unseen injection molding tools


Employee at Addifab, assembling the 3D Printer.
An enabling foundation for unseen opportunities

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