This project was done as a promotional giveaway - a 2.5mm hex key is a standard for 3D printer hardware, so I designed an overmolded handle that we could give to customers. This project is still in development, but a TPU 95A mold accepts an injection from a syringe with Smooth-On casting resin (material testing ongoing). 1/4' bolts maintain pressure on the mold, and the TPU deflects enough to create a seal around the cavity.
This mold is designed to be reprinted rapidly in the case of a failure, and takes half a workday to reproduce!
