For our Final exam project at UJ University we where briefed to design a Fly Swatter that is based on a promotional brand such as doom or any bug killer. The design of the fly is to be based on a contemporary design as well. 

After creating a lot of mock to explore how the different shapes feel in our hands and how the different shapes interact with our hands as well i have decided to go with this handle, because this handle is the most ergonomic design that i could create. Because the has to be has to be specific to injection moulding i had to make sure that i had even wall thicknesses all over the design in order to create a efficient injection moulding design. I insured that there are also a lot of rounded radius's.  

For my prototype i used a polyurethane rubber to use it as a platform as a plastic to use for injection moulding. 

So i first had to do a first half of the moulding using a silicone smooth cast 1 liter tub for the bottom half then after that i left it to set and then i casted the second half of the mould with the same silicone which was also a 1 liter tub. i had to use weights to push down the flap top part of the fly swatter in order to mould it accurately. After the mould was set and ready to start the injection moulding process i put an injection into the gate of the mould then i built a seal around the injector to create a little pressure. Then i injected the measured amount of plastic into the mould cavity the cavity flooded over. I left the plastic to set and whala a fly swatter emerged with a lot of flashing that had to be fettled. 

Here are a few rendered versions of the fly swatter in solid works. I just used a lot of fillets and extrusions and cut extrusions to create it in solid works.

Here are some failed attempts along with the final 2 product. An big issue that i encountered was bubbles that where trapped inside the thick slurry of plastic.