A method for improving the impact resistance of an extrusion blow molded article by extrusion blow molding an ultra-high IV polymer resin having an IV of at least 0.9 dL/g, wherein the extrusion blow molding is carried out in a mold with a texturized base surface such that a base surface of the extrusion blow molded article is textured.

A mold assembly for molding articles including a surface insert and a surface insert support configured to support at least a portion of the surface insert. In embodiments, the surface insert is configured to form at least a portion of a molded article and the surface insert has a thickness within a range of about 0.250 or 0.300 inches and about 1.500 inches or about 2.25 inches. The mold assembly may include a holding unit, and at least a portion of the surface insert and/or at least a portion of the surface insert support may be formed by additive manufacturing.

A tooling system for fabricating a composite structure comprising a printed thermoplastic material tooling component having a non-tooling surface and a tooling surface, wherein the tooling surface defines a predetermined shape for the composite structure. The tooling system may further comprise a printed thermoplastic material tooling base structure having a plurality of non-tooling surfaces to support the printed thermoplastic material tooling component during layup or cure. The printed thermoplastic material tooling base structure may employ a support structure, such as a honeycomb support structure or a filler material.

A modular system for blow molding a container. The system may include a first portion, a second portion, and a third portion. The first portion and second portion may each include a shell, a mold removably coupled to the shell, and a top plate. The third portion may include a base and a base mold. The molds may be 3D printed. The molds together may define a blow mold cavity. The modular system may be used at lab scale, pilot scale, or full production scale. The molds may be durable and smooth enough for full production scale. Some embodiments are directed to methods for making a modular system for blow molding a container.