Dual-Cavity Polyurethane Mold

Customer requirements outgrew the existing molds. Rather than simply scaling up the current design, I proposed an entirely new mold that would increase production capacity and improve the operator experience.

The previous process relied on removable bolts and frequent mallet use because side bars became misaligned during reassembly.

Before developing the new design, I completely disassembled and rebuilt the existing molds. This allowed me to understand how every component worked, identify alignment and usability weaknesses, and determine which features should be retained, redesigned, or eliminated.

The redesigned mold produces two parts while occupying the same floor space. Hinged faces and quick-release clamps eliminate removable hardware and maintain alignment between mold components.

The larger design met the updated product dimensions while improving speed, repeatability, and ergonomics.

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I led weekly cross-functional meetings to present design decisions, review milestones, discuss manufacturing feasibility, and track cost and schedule.

I coordinated with machinists, mechanical engineers, chemical engineers, process engineers, finance, purchasing, and production. Before leaving, I finalized the design work, organized documentation, sourced materials, and completed a formal handoff.