Plugs in action
Removing parts from the mold
Bear Plugs are injection-molded bicycle bar plugs, both a fun accent and necessary safety component for cycling.
The plugs were molded on a vertical Arburg injection molder, in molds I designed and CNC-machined. I used an unconventional insert-based injection mold and flexible plastic to create undercut geometry.
Though the end result is simple, this project taught me the difference between making one and making many, and how to optimize material, time and manufacturing process.
A range of failed prototypes with fill, flash, color, dimension, and other imperfections
A range of CNC-machined mold prototypes
