Rapid Tooling

Question 1

Am/Rp applications - Rapid Tooling?

Answer 1

• Tooling is traditionally, most expensive and time consuming manufacturing process. Characteristics are, - Toughness and wear resistance. - Complex geometries. - Very High dimensional accuracy 0.01mm or better. -Very high surface finish.

Question 2

Indirect tooling?

Answer 2

Prototypes are used as patterns for making moulds and dies.

Question 3

Direct tooling?

Answer 3

Production files are cast as net shape tools directly from CAD files.

Question 4

Indirect tooling?

Answer 4

Prototypes are used as patterns for making moulds and dies used in a number of manufacturing processes. • Vacuum Casting - Rapid prototype pattern is cast into a silicon rubber mould (RTV) • Sand Casting - Rapid prototyping pattern made by laminated object manufacturing resembles the traditionally used wooden pattern. • Investment Casting - Rapid prototyping is made by laminated object manufacturing from paper are often used as they are dimensionally stable with the paper shell burning out; Rapid prototyping patterns made by Stereolithography from the resin consisting of hollow ( internal hexagonal support structure)

Question 5

Rapid tooling - Investment Casting made by Stereolithography.

Answer 5

1) Pattern creation 2) Tree Assembly 3) Insert into Flask 4) Fill with investment 5) Wax melt-out/burnout 6) Fill mold with metal 7) Cool 8) Finish (Grind polish)

Question 6

Direct tooling?

Answer 6

•Hard tooling is made directly from CAD data without fabricating a pattern first. 1) Selectively Sintering of polymer-Coated steel pellets together to produce a metal mould mould, burn off the polymer binder and infiltrate with copper. 2) Development of ceramic composite materials using Direct Shell Production Casting techniques. 3) Construct of Sand moulds directly from CAD data using Sand-Like material (foundry-type sand) that is sintered into moulds.

Question 7

Rapid Tooling Advantages?

Answer 7

• Advantages • less dependant on highly skilled pattern makers. • Reduction in high labour costs. •Shorter lead times in the production of patterns and moulds using the concept of net shaped tools. • Optimised Mould Design possible; chilling - and cooling-channel Placement possibly leading to reduced cycle times.

Question 8

Rapid Tooling Limitations?

Answer 8

Limitations • Potentially Reduced Tool life. • Limited Material range; often only specialised and proprietary materials and processes available.

Question 9

Rapid Tooling - Investment Casting

• Patterns made by Steriolothography

Answer 9

1 - Pattern creation

2 - Tree Assembly

3 - insert into flask

4. Fill with investment
5. Wax melt-out/burnout
6. Fill mold with metal
7. Cool
8. Finish (Grind)