After watching the program and reviewing this printed material, the viewer will understand the principles of rapid tooling design and processes.

Size: px
Start display at page:

Download "After watching the program and reviewing this printed material, the viewer will understand the principles of rapid tooling design and processes."

Transcription

1 Training Objective After watching the program and reviewing this printed material, the viewer will understand the principles of rapid tooling design and processes. Design aspects are detailed Indirect and direct processes are explored Mold creation is demonstrated Cooling and cycle times are examined Rapid Tooling Basics Rapid tooling broadly describes any mold-making process that can create tools quickly and with minimum direct labor. The rapid tooling concept includes tool-making approaches that apply additive, subtractive, and pattern-based processes. All can be applied in a variety of applications from injection molding to casting and sheet metal stamping operations. Rapid tooling can be deployed in two forms: Indirect tooling Direct tooling Indirect tooling incorporates pattern-based methods where the tool is cast from a rapid prototype that depicts the part to be molded. Direct tooling is a method where the mold, inserts, or other components are made directly by a rapid prototyping machine. Rapid prototyping, which is also called additive fabrication, additive manufacturing, and freeform fabrication, grows physical objects directly from 3D CAD data by bonding layers of material. The process is particularly suited to prototype mold creation. The additive nature of the process allows intricate details and complex shapes to be manufactured with little effort and no impact on time or cost. Also, much of the process is completed without direct labor or a machine operator in attendance. There are numerous rapid prototyping technologies used today including: Stereolithography Laser sintering Fused deposition modeling Various 3D printing processes Although most rapid prototyping technologies can be used for indirect, pattern-based rapid tooling, the bulk of the direct tooling work uses a metal-based technology such as direct-metal laser-sintering, selective laser melting or laser cusing. Indirect Rapid Tooling Processes Indirect rapid tooling processes produce molds by forming them from a pattern. A common example of this technique is RTV, or room temperature vulcanized rubber molding. Typically, the pattern used to produce this type of indirect rapid tooling is constructed using a rapid prototyping machine. Following the pattern s construction, it is postprocessed to prepare it for mold creation. Once post-processed, development of the first mold half typically begins by securing the pattern in oil-based clay, or other building materials, and constructing the parting line. Fundamentals of Tool Design Study Guide, DV08PUB3-1 -

2 Silicone RTV molding material is then poured around the pattern and allowed to cure. Typically, it is necessary to apply a vacuum to either the RTV molding material before pouring, or the tooling assembly after pouring, to remove air bubbles from the molding material. Once the silicone has cured, the second mold half is prepared and poured. A gate for injection is added along with venting to allow air in the mold to escape. Once the second mold half cures, the pattern is removed and the mold is prepared for use. RTV tooling can be used to mold small to medium quantities of parts out of a large variety of urethane, epoxy, or other polymer materials. RTV tooling can typically be used to mold many parts before replacement tooling becomes necessary. The tool life depends on the casting material, accuracy, finish requirements, and the complexity of the part geometry. Dozens of simple parts can be produced from a single silicone rubber mold, but is typical if the parts are more complex. Direct Tooling Processes Direct rapid tooling typically uses metal-based rapid prototyping technologies to generate molds and mold elements. These processes are still emerging and developing as new technologies, materials, and system features are introduced. The principle advantage of direct tooling is its time and cost-saving aspects, often up to 66% over other mold-making methods. Each element of the tool is evaluated separately to determine the best construction process. Rapid tooling can be combined with machined metal cavities and purchased mold bases. This digression from traditional machining and manufacturing processes promotes the use of rapid prototyping-based tooling when elements of a mold are intricate and highly detailed. The most common metal-based rapid prototyping methods are: Direct metal laser sintering (DMLS) Selective laser melting (SLM) These additive processes produce tools made of stainless steel, cobalt, chromium, maraging steel, titanium, and alloy blends. Additionally, some companies have found success using stereolithography to create composite-plastic mold inserts using resins such as the ceramic filled nanotool to produce small, short-run molds for injection molding. The basic, four-step process for constructing injection molds with rapid tooling techniques is the same as that when machining a mold: 1. Tool design 2. Component building 3. Tool assembly 4. Injection molding Tool design involves determining what components are to be rapid tooled or machined. This includes the design of the tool inserts and the pockets in which they will seat in the mold core, cavity, or base. Other design factors include draft angles, gating, venting, and reinforcement ribs. Component building includes the simultaneous machining of mold elements while rapid prototyping of the mold inserts is taking place. Once rapid prototyping is complete, the inserts are post-processed. For nanotool inserts, post-processing includes parts washing, support removal and ultraviolet curing. For the DMLS and SLM processes, this includes removal of supports and any excess metal powder. While the build platform may be cut away from the metal insert, it is often included as an integral mold element. Fundamentals of Tool Design Study Guide, DV08PUB3-2 -

3 The rapid prototyping layering process results in stair-stepping when insert surfaces are not vertical or horizontal. Such steps may be removed by machining or polishing. However, this may not be possible and may make the molded part difficult to eject or affect the part s appearance. Stock added to the insert s design must be finished to size before assembly. This stock can be removed by grinding, milling, or electrical discharge machining (EDM). Undersized holes can be reamed to size. It is critical to avoid excessive secondary operations for the purpose of holding desired tolerances and improving surface finish. If a significant amount of machining is required to deliver the surface finish and accuracy needed for the injection mold, the time for machine set up and operation will negate the time advantage that rapid tooling offers. Tool assembly involves mounting the inserts into the pockets that have been machined to accept them. All other components are added to complete the injection mold. The mold is then mounted in the machine for injection molding. Because nanotool inserts do not have the mechanical properties of metal inserts, shot size and pressure application are critical in filling the mold. Additionally nanotool material acts as an insulator requiring oversized cooling channels. As heat retention is also a problem, cycle times must be increased. For most thermoplastics, an increase of 30 to 60 seconds is adequate. DMLS and SLM metal inserts don t require any special changes to the injection molding machine. The strength of the metal inserts eliminates the need to ease into shot size and pressure and, their cooling rate is similar to that of the other mold components, allowing consistent cooling. Since complexity is not a concern when additively constructing a mold and its inserts, rapid tooling can accommodate cooling channels that twist, bend, and contort to follow the contours of the mold s cavity. This circulates coolant across the entire mold cavity or in the hottest spots of the mold. The conformal cooling channels, when designed effectively, have been reported to decrease cycle times by as much as 40 percent when compare to the straight-line, gun-drilled channels of conventionally made injection molds. Fundamentals of Tool Design Study Guide, DV08PUB3-3 -

4 Review Questions 1. Indirect tooling is: a. similar to conventional injection molding b. template based c. pattern based d. produced using stereolithography 2. A direct rapid tooling method well suited for small, short-run mold inserts is: a. RTV b. stereolithography c. direct metal laser sintering d. selective laser melting 3. RTV refers to: a. a rapid prototyping machine b. high temperature silicone rubber molding c. rubber molding d. high pressure injection molding 4. With indirect tooling, tool life is not dependent on: a. part geometry b. the casting material c. finish requirements d. the pattern material 5. Direct tooling often results in time and cost savings of up to: a. 66% b. 64% c. 62% d. 60% 6. A nanotool is a ceramic filled type of: a. polyester b. epoxy c. urethane d. resin 7. The electrical discharge machining process can be used to: a. size reamed holes b. generate large mold pockets c. polish mold halves d. remove excess stock from the inserts 8. Nanotool inserts can act as: a. insulators b. electrical conductors c. cooling devices d. vulcanizing agents 9. Conformal cooling refers to: a. indirect tooling cooling channels b. contoured cooling channels c. cooling fluid selection d. oversized cooling channels Fundamentals of Tool Design Study Guide, DV08PUB3-4 -

5 Answers 1. c 2. b 3. c 4. d 5. a 6. d 7. d 8. a 9. b Fundamentals of Tool Design Study Guide, DV08PUB3-5 -

Rapid Prototyping. Training Objective

Rapid Prototyping. Training Objective Training Objective After watching the program and reviewing this printed material, the viewer will understand the principles and practical applications of Rapid Prototyping. Basic concepts are explained

More information

Your Single Source For Custom Parts.

Your Single Source For Custom Parts. Stereolithography (SLA) Stereolithography prototypes are constructed from a liquid photopolymer that is selectively cured using an ultraviolet laser. 50 Well Specimen Tray Focus group and presentation

More information

Allison Rae Paramount Industries Rhode Island School of Design ID 87. Prototyping Overview

Allison Rae Paramount Industries Rhode Island School of Design ID 87. Prototyping Overview Allison Rae Paramount Industries Rhode Island School of Design ID 87 Prototyping Overview Prototyping for Mechanical Parts Paramount Industries Started as prototyping vendor, then added: Industrial Design

More information

3D Printing for Silicone Molding

3D Printing for Silicone Molding 3D Printing for Silicone Molding INTRO Currently among all the 3D printing technologies FDM is the most commonly used technology for the prototyping. We can use 3D printing for making 2-3 parts but if

More information

Plastic Injection Molds

Plastic Injection Molds Training Objective After watching the program and reviewing this printed material, the viewer will become familiar with the variety, design, and productive use of plastic injection molds. Mold components

More information

MOLDS FOR CASTING VEHICLE PARTS

MOLDS FOR CASTING VEHICLE PARTS MOLDS FOR CASTING VEHICLE PARTS N. Zaimović-Uzunović, University of Sarajevo, Faculty of Mechanical Engineering in Zenica I. Karabegović, University of Bihać, Technical Faculty in Bihać D. Ćurić, Foundry

More information

Application Notes. Design Rules for DMLS. 1 Geometries

Application Notes. Design Rules for DMLS. 1 Geometries Design Rules for DMLS This document provides guidelines on how to design parts to be built using Direct Metal Laser Sintering (DMLS) with EOSINT M systems in order to ensure high quality and cost-effective

More information

Understanding Manufacturing. Manufacturing Processes. Understanding Manufacturing. Understanding Manufacturing. Understanding Manufacturing

Understanding Manufacturing. Manufacturing Processes. Understanding Manufacturing. Understanding Manufacturing. Understanding Manufacturing Manufacturing Processes Chapter 8 Manufacturing involves making products from raw materials by various processes, machinery, and operations Manufacturing has the important function of adding value Manufacturing

More information

Ningbo Yinzhou Keao Prototyping & Mould Factory Services include : CNC machining prototypes,

Ningbo Yinzhou Keao Prototyping & Mould Factory Services include : CNC machining prototypes, Ningbo Yinzhou Keao Prototyping & Mould Factory Services include : CNC machining prototypes, STEREOLITHOGRAPHY (SLA) Selective Laser Sintering (SLS) RTV MOLDING AND CAST URETHANE PROTOTYPES Tel : +86 574

More information

DESIGNING FOR THE DMLS PROCESS JONATHAN BISSMEYER Senior Quality Engineer

DESIGNING FOR THE DMLS PROCESS JONATHAN BISSMEYER Senior Quality Engineer DESIGNING FOR THE DMLS PROCESS JONATHAN BISSMEYER Senior Quality Engineer ABOUT PROTO LABS OUR EQUIPMENT Concept Laser M2 and Mlab machines DESIGNING FOR DMLS Not a replacement for traditional machining,

More information

Casting. Training Objective

Casting. Training Objective Training Objective After watching the program and reviewing this printed material, the viewer will learn the essentials of the various metal casting processes used in industry today. The basic principles

More information

Tool Design and Concurrent Engineering using Rapid Tooling Construction Methods

Tool Design and Concurrent Engineering using Rapid Tooling Construction Methods Section Number 3563 Tool Design and Concurrent Engineering using Rapid Tooling Construction Methods Nicole Hoekstra Engineering Technology Department Western Washington University Abstract Prior to rapid

More information

Mechanical properties can be permanently altered by either thermal or mechanical treatment. Those properties include:

Mechanical properties can be permanently altered by either thermal or mechanical treatment. Those properties include: Training Objective After watching the program and reviewing this printed material, the viewer will become familiar with further aspects of tool design by exploring the materials used in toolmaking. Tool

More information

Instrument and Control Systems Laboratory 1 (0-3) Laboratory experiments on topics covered in instrument and control systems.

Instrument and Control Systems Laboratory 1 (0-3) Laboratory experiments on topics covered in instrument and control systems. 01211231 Conventional and Computer-Controlled Machines 3 (3-0) Prerequisite : 01208281 Conventional machine for tools: turning, drilling, tapping, milling, grinding, cutting, punching, boring and bending;

More information

Tutorial: Rapid Prototyping Technologies

Tutorial: Rapid Prototyping Technologies 1. Introduction Tutorial: Rapid Prototyping Technologies Rapid prototyping (RP) is a new manufacturing technique that allows for fast fabrication of computer models designed with three-dimension (3D) computer

More information

Additive Manufacturing: Processes and Standard Terminology

Additive Manufacturing: Processes and Standard Terminology Additive Manufacturing: Processes and Standard Terminology Gary Coykendall Copyright Edmonds Community College 2012; Permission granted for use and reproduction for educational purposes only. Abstract

More information

Injection molding overview

Injection molding overview Injection molding overview This injection molding overview is designed to help our customers understand the process of injection molding and mold-making. Please read it fully as it helps to define what

More information

How to Effectively Move from 3D Printing to Injection Molding. Tony Holtz Technical Specialist, Proto Labs

How to Effectively Move from 3D Printing to Injection Molding. Tony Holtz Technical Specialist, Proto Labs How to Effectively Move from 3D Printing to Injection Molding Tony Holtz Technical Specialist, Proto Labs Overview 3D Printing CNC Machining Injection Molding Design Considerations for Injection Molding

More information

Rapid prototyping. CAD / lecture. October 5, 2010. TO&I Vermelding onderdeel organisatie

Rapid prototyping. CAD / lecture. October 5, 2010. TO&I Vermelding onderdeel organisatie 1 Rapid prototyping is: Rapid prototyping is an additive (layered) digital fabrication technology Layers of material are added forming the final 3d physical model The digital data of the virtual 3d model

More information

GLOBAL MANUFACTURING. ARAUJO, Anna Carla AUG, 2015 Mechanical Engineering Department POLI/COPPE/UFRJ

GLOBAL MANUFACTURING. ARAUJO, Anna Carla AUG, 2015 Mechanical Engineering Department POLI/COPPE/UFRJ GLOBAL MANUFACTURING ARAUJO, Anna Carla AUG, 2015 Mechanical Engineering Department POLI/COPPE/UFRJ Workpiece Presentation Powder Metallurgy and Additive Manufacturing [#7] Powder Metallurgy PM parts can

More information

Powder Metallurgy. Training Objective

Powder Metallurgy. Training Objective Training Objective After watching the program and reviewing this printed material, the viewer will gain a knowledge and understanding of the basics of powder metallurgy. Types of particles are explained.

More information

Plastic Injection Molding

Plastic Injection Molding Training Objective After watching this video and reviewing the printed material, the student/trainee will understand the principles and physical operations of the plastic injection molding process. An

More information

1) Introduction to 3D Printing

1) Introduction to 3D Printing 1) Introduction to 3D Printing General explanation of 3D Printing: A method of manufacturing known as Additive manufacturing, due to the fact that instead of removing material to create a part, the process

More information

RAPID PROTOTYPING. Learning Objectives: By the end of the lecture the student should be able to: Explain the fundamentals of Rapid Prototyping

RAPID PROTOTYPING. Learning Objectives: By the end of the lecture the student should be able to: Explain the fundamentals of Rapid Prototyping RAPID PROTOTYPING Learning Objectives: By the end of the lecture the student should be able to: Explain the fundamentals of Rapid Prototyping Outline and explain differences of Rapid Prototyping Technologies

More information

SERVICES AND CAPABILITIES. 1. Rapid prototyping

SERVICES AND CAPABILITIES. 1. Rapid prototyping SERVICES AND CAPABILITIES 1. Rapid prototyping What is rapid prototyping? Rapid prototyping (RP) or more recently Free Form Fabrication refers to the fabrication of a physical, three-dimensional part of

More information

Glossary. 3D Animation Using computer software to create and animate a three-dimensional representation of image data.

Glossary. 3D Animation Using computer software to create and animate a three-dimensional representation of image data. Glossary # 2D Control Drawing A line drawing showing various views of a product with details such as material, surface finish, volume, tolerances and critical dimensions. 3D Animation Using computer software

More information

Effective Cooling Method for Spin Casting Process

Effective Cooling Method for Spin Casting Process Effective Cooling Method for Spin Casting Process Yong-Ak Song, Sehyung Park, Yongsin Kwon Korea Institute of Science and Technology KIST, CAD/CAM Research Center P.O. Box 131, Cheongryang, Seoul, Korea

More information

APPLYING RAPID TOOLING FOR INJECTION MOLDING & DIE CASTING From a RT users perspective

APPLYING RAPID TOOLING FOR INJECTION MOLDING & DIE CASTING From a RT users perspective APPLYING RAPID TOOLING FOR INJECTION MOLDING & DIE CASTING From a RT users perspective Glenn Anderson Senior Engineer, Research and Development Southco, Inc. RPA/SME Technical Forum on Rapid Tooling 20

More information

Choosing the Right Rapid Prototyping Source for Your Product Development Program. Phillips Plastics Corporation November 2009

Choosing the Right Rapid Prototyping Source for Your Product Development Program. Phillips Plastics Corporation November 2009 Choosing the Right Rapid Prototyping Source for Your Product Development Program Phillips Plastics Corporation November 2009 Successful prototyping begins with mechanical design that will operate properly

More information

Determining the Right Molding Process for Part Design

Determining the Right Molding Process for Part Design Determining the Right Molding Process for Part Design How RIM Molding Advantages Compare with Traditional Production Technologies Page 2 Introduction This White Paper details the part production processes

More information

ON-DEMAND PARTS MANUFACTURING. Quickparts

ON-DEMAND PARTS MANUFACTURING. Quickparts ON-DEMAND PARTS MANUFACTURING Quickparts On-demand parts manufacturing services Using our additive and traditional manufacturing technologies, bring your design to life and create real functional end-use

More information

Somos Materials. Injection Molding Using Rapid Tooling

Somos Materials. Injection Molding Using Rapid Tooling Somos Materials Injection Molding Using Rapid Tooling Introduction Testing a new design before costly tooling is created can save companies time and money. For many years, the only process available to

More information

RAPID PROTOTYPING Brandenburg University of Technology Cottbus February 2010 SEPPO AARNIO

RAPID PROTOTYPING Brandenburg University of Technology Cottbus February 2010 SEPPO AARNIO RAPID PROTOTYPING Brandenburg University of Technology Cottbus 4.-5. February 2010 15/02/2010 SEPPO AARNIO THREE PHASES OF DEVELOPMENT LEADING TO RAPID PROTOTYPING MANUAL PROTOTYPING SOFT or VIRTUAL PROTOTYPING

More information

Choosing the Right Rapid Prototyping Source for Your Product Development Program. Phillips-Medisize Corporation November 2009

Choosing the Right Rapid Prototyping Source for Your Product Development Program. Phillips-Medisize Corporation November 2009 Choosing the Right Rapid Prototyping Source for Your Product Development Program Phillips-Medisize Corporation November 2009 Successful prototyping begins with mechanical design that will operate properly

More information

Chapter 5 POWDER-BASED RAPID PROTOTYPING SYSTEMS

Chapter 5 POWDER-BASED RAPID PROTOTYPING SYSTEMS Chapter 5 POWDER-BASED RAPID PROTOTYPING SYSTEMS 5.1 3D SYSTEMS SELECTIVE LASER SINTERING (SLS) 5.1.1 Company 3D Systems Corporation was founded by Charles W. Hull and Raymond S. Freed in 1986. The founding

More information

The creation of tooling using the selective laser sintering process. Scott Schermer S.C. Johnson

The creation of tooling using the selective laser sintering process. Scott Schermer S.C. Johnson The creation of tooling using the selective laser sintering process Scott Schermer S.C. Johnson 1 TOOLING utilizing traditional rapid prototyping machines to produce metal inserts. 2 LaserForm ST-100?

More information

Overview 內 容 快 速 原 型 科 技 中 心 服 務 激 光 抄 數 原 理 快 速 原 型 技 術 鈦 金 屬 鑄 造 於 其 產 品 開 發 之 應 用 激 光 焊 接 技 術 快 速 原 型 一 站 式 個 案 研 究 參 觀 快 速 原 型 科 技 中 心

Overview 內 容 快 速 原 型 科 技 中 心 服 務 激 光 抄 數 原 理 快 速 原 型 技 術 鈦 金 屬 鑄 造 於 其 產 品 開 發 之 應 用 激 光 焊 接 技 術 快 速 原 型 一 站 式 個 案 研 究 參 觀 快 速 原 型 科 技 中 心 Overview 內 容 快 速 原 型 科 技 中 心 服 務 激 光 抄 數 原 理 快 速 原 型 技 術 鈦 金 屬 鑄 造 於 其 產 品 開 發 之 應 用 激 光 焊 接 技 術 快 速 原 型 一 站 式 個 案 研 究 參 觀 快 速 原 型 科 技 中 心 Technology Integrated Product Development Cycle Product Design

More information

3D Printing/Additive Manufacturing and Short Run Manufacturing Time Options! Presented by Charles L. Koch Vice-President 3Axis Development, Inc.

3D Printing/Additive Manufacturing and Short Run Manufacturing Time Options! Presented by Charles L. Koch Vice-President 3Axis Development, Inc. 3D Printing/Additive Manufacturing and Short Run Manufacturing Time Options! Presented by Charles L. Koch Vice-President 3Axis Development, Inc. WHERE DID IT ALL BEGIN? 1970 s First 3D CAD Software 1988

More information

NetShape - MIM. Metal Injection Molding Design Guide. NetShape Technologies - MIM Phone: 440-248-5456 31005 Solon Road FAX: 440-248-5807

NetShape - MIM. Metal Injection Molding Design Guide. NetShape Technologies - MIM Phone: 440-248-5456 31005 Solon Road FAX: 440-248-5807 Metal Injection Molding Design Guide NetShape Technologies - MIM Phone: 440-248-5456 31005 Solon Road FAX: 440-248-5807 Solon, OH 44139 solutions@netshapetech.com 1 Frequently Asked Questions Page What

More information

Casting Methods. Prof. Juhani Orkas

Casting Methods. Prof. Juhani Orkas Casting Methods Prof. Juhani Orkas Overview Google Books: Handbuch für technisches Produktdesign Lost mould Permanent pattern Sand casting Manual shaping Mechanical shaping Shell moulding Ceramic moulding

More information

Challenge. Today s manufacturers and. product designers demand. fast turnaround of quality parts. to remain competitive and

Challenge. Today s manufacturers and. product designers demand. fast turnaround of quality parts. to remain competitive and Challenge Today s manufacturers and product designers demand fast turnaround of quality parts to remain competitive and effectively bring new products to market. But beyond speed and efficiency, effective

More information

Casting Made Simple and Predictable. Presented by Ferdinand Mels

Casting Made Simple and Predictable. Presented by Ferdinand Mels Casting Made Simple and Predictable. Presented by Ferdinand Mels To download this file as a PDF document please go to : www.7-8ths.info The Master Model (part to be cast) : When is it cost and time effective

More information

Plastics Processing. Plastics can be machined, cast, formed, and joined with relative ease requiring little post-processing or surfacefinish

Plastics Processing. Plastics can be machined, cast, formed, and joined with relative ease requiring little post-processing or surfacefinish Plastics Processing Plastics Processing Plastics can be machined, cast, formed, and joined with relative ease requiring little post-processing or surfacefinish operations Plastics melt or cure at relative

More information

CLASSIFICATIONS OF INJECTION MOLDS

CLASSIFICATIONS OF INJECTION MOLDS CLASSIFICATIONS OF INJECTION MOLDS General Notes The following classifications are guidelines to be used in obtaining quotations and placing orders for uniform types of molds. It is our desire, through

More information

Fundamentals of Design for Plastic Injection Molding. Kelly Bramble

Fundamentals of Design for Plastic Injection Molding. Kelly Bramble Fundamentals of Design for Plastic Injection Molding Kelly Bramble 1 Fundamentals of Design for Plastic Injection Molding Copyright, Engineers Edge, LLC www.engineersedge.com All rights reserved. No part

More information

the runnerless types of molds are explained post molding operations are described the basic methods of applied decoration methods are examined

the runnerless types of molds are explained post molding operations are described the basic methods of applied decoration methods are examined Training Objectives After watching the video and reviewing this printed material, the viewer will gain knowledge and understanding of the various plastic finishing processes used in industry and their

More information

MANUFACTURING THE FUTURE

MANUFACTURING THE FUTURE Paul Miller 803-554-3590 paul.miller@3dsystems.com MANUFACTURING THE FUTURE PAUL MILLER DIRECTOR OF SALES WWW.3DSYSTEMS.COM NYSE:DDD 2013 3DSYSTEMS A 3D PRINTER FOR YOU RESULTING IN UNMATCHED 3D PRINTER

More information

Choosing the Right Rapid Prototype Source for Your Product Development Program. Phillips Plastics Corporation November 2009

Choosing the Right Rapid Prototype Source for Your Product Development Program. Phillips Plastics Corporation November 2009 Choosing the Right Rapid Prototype Source for Your Product Development Program Phillips Plastics Corporation November 2009 Introduction Being able to create prototype injection molded components and assemblies

More information

D-M-E MoldFusion 3D Metal Printing. Mold tooling technology for complex applications conformal cooling, rapid tooling and beyond

D-M-E MoldFusion 3D Metal Printing. Mold tooling technology for complex applications conformal cooling, rapid tooling and beyond D-M-E MoldFusion 3D Metal Printing Mold tooling technology for complex applications conformal cooling, rapid tooling and beyond PAGE 61 Build The Unmachineable You ve seen it before the part demands cooling

More information

Processing of Non- Metals Dr. Inderdeep Singh Department of Mechanical and Industrial Engineering Indian Institute of Technology, Roorkee

Processing of Non- Metals Dr. Inderdeep Singh Department of Mechanical and Industrial Engineering Indian Institute of Technology, Roorkee Processing of Non- Metals Dr. Inderdeep Singh Department of Mechanical and Industrial Engineering Indian Institute of Technology, Roorkee Module - 4 Plastics: properties and processing Lecture - 7 Rotational

More information

CHAPTER 2 INJECTION MOULDING PROCESS

CHAPTER 2 INJECTION MOULDING PROCESS CHAPTER 2 INJECTION MOULDING PROCESS Injection moulding is the most widely used polymeric fabrication process. It evolved from metal die casting, however, unlike molten metals, polymer melts have a high

More information

Brief Report on machines available in the 3D Printers market and their characteristics

Brief Report on machines available in the 3D Printers market and their characteristics Brief Report on machines available in the 3D Printers market and their characteristics by AJIU Asociaciòn de investigacion de la industria del juguete, conexas y afines, Contenido 1. 3D PRINTING... 3 2.

More information

As published in PIM International

As published in PIM International As published in PIM International www.pim-international.com 64 Powder Injection Moulding International September 2012 Rapid prototyping of highperformance ceramics opens new opportunities for the CIM industry

More information

Fokus: PLAST Lund 4-5 maj Lunds Tekniske Högskola

Fokus: PLAST Lund 4-5 maj Lunds Tekniske Högskola Fokus: PLAST Lund 4-5 maj Lunds Tekniske Högskola Production of injection moulds using AM technology - LaserCUSING Martin Nielsen, Product Manager Concept-Laser Agenda Who is Signcom Our Customers What

More information

Direct Metal Deposition: Tomorrow s Technology Today

Direct Metal Deposition: Tomorrow s Technology Today Direct Metal Deposition: Tomorrow s Technology Today Session Agenda Introduction of Speaker Overview of Direct Metal Deposition Technology. Review Unique Applications Enabled by DMD. Case Studies Tool

More information

RAPID PROTOTYPING. Principles and Applications. RAFIQ NOORANI, Ph.D. Professor of Mechanical Engineering Loyola Marymount University Los Angeles, CA

RAPID PROTOTYPING. Principles and Applications. RAFIQ NOORANI, Ph.D. Professor of Mechanical Engineering Loyola Marymount University Los Angeles, CA RAPID PROTOTYPING Principles and Applications RAFIQ NOORANI, Ph.D. Professor of Mechanical Engineering Loyola Marymount University Los Angeles, CA WILEY JOHN WILEY & SONS, INC. CONTENTS Preface Acknowledgments

More information

e-manufacturing Solutions

e-manufacturing Solutions Laser-sintering produces directly from 3D CAD data fast, flexibly and cost-effectively. Process and Benefits Process Laser-sintering is a generative layer manufacturing technology. Any three-dimensional

More information

RAPID PROTOTYPING. Dr. M. Sayuti, ST.,M.Sc JURUSAN TEKNIK INDUSTRI FAKULTAS TEKNIK UNIVERSITAS MALIKUSSALEH 2016

RAPID PROTOTYPING. Dr. M. Sayuti, ST.,M.Sc JURUSAN TEKNIK INDUSTRI FAKULTAS TEKNIK UNIVERSITAS MALIKUSSALEH 2016 RAPID PROTOTYPING Dr. M. Sayuti, ST.,M.Sc JURUSAN TEKNIK INDUSTRI FAKULTAS TEKNIK UNIVERSITAS MALIKUSSALEH 2016 CONTENTS OVERVIEW INTRODUCTION CLASSIFICATION METHODOLOGY TYPES OF RP APPLICATION PRODUCT

More information

Juha Kotila, Tatu Syvanen, Jouni Hanninen, Jan-Erik Lind and Olli Nyrhila. EOS Finland Aholantie Rusko, Finland

Juha Kotila, Tatu Syvanen, Jouni Hanninen, Jan-Erik Lind and Olli Nyrhila. EOS Finland Aholantie Rusko, Finland DIRECT METAL LASER SINTERING IN 20 µm LAYER THICKNESS Juha Kotila, Tatu Syvanen, Jouni Hanninen, Jan-Erik Lind and Olli Nyrhila EOS Finland Aholantie 17 21290 Rusko, Finland ABSTRACT The latest developments

More information

Rapid Prototyping & Rapid Tooling. Corso di Sistemi integrati di Produzione A.A Prof. G. A. Berti

Rapid Prototyping & Rapid Tooling. Corso di Sistemi integrati di Produzione A.A Prof. G. A. Berti Rapid Prototyping & Rapid Tooling Corso di Sistemi integrati di Produzione A.A.2004-05 Prof. G. A. Berti Rapid Prototyping achievements Reduction in prototyping times (from weeks to days) Reduction in

More information

ORNL Manufacturing Demonstration Facility Technical Collaboration Final Report

ORNL Manufacturing Demonstration Facility Technical Collaboration Final Report ORNL Manufacturing Demonstration Facility Technical Collaboration Final Report Using Direct Metal Deposition to Fabricate Mold Plates for an Injection Mold Machine Allowing for the Evaluation of Cost Effective

More information

PERMANENT MOLD PROCESS

PERMANENT MOLD PROCESS PERMANENT MOLD PROCESS PERMANENT MOLD CASTING Permanent Mold refers to the tooling used to produce the castings. The molds or dies are usually made of high alloy iron or steel (both very dense) and have

More information

Hydroforming. Training Objective

Hydroforming. Training Objective Training Objective After watching the video and reviewing this printed material, the viewer will gain knowledge and understanding of the hydroforming process and its use in manufacturing sheet metal parts.

More information

www.studymafia.org Seminar report Rapid Prototyping Submitted in partial fulfillment of the requirement for the award of degree Of Mechanical

www.studymafia.org Seminar report Rapid Prototyping Submitted in partial fulfillment of the requirement for the award of degree Of Mechanical A Seminar report On Rapid Prototyping Submitted in partial fulfillment of the requirement for the award of degree Of Mechanical SUBMITTED TO: SUBMITTED BY: www.studymafia.org www.studymafia.org Preface

More information

What is a mold? Casting. Die casting. Injection Molding Machine. Injection Molding. 2.008 Design & Manufacturing II. Spring 2004

What is a mold? Casting. Die casting. Injection Molding Machine. Injection Molding. 2.008 Design & Manufacturing II. Spring 2004 2.008 Design & Manufacturing II What is a mold? From Webster: a cavity in which a substance is shaped: as (1) : a matrix for casting metal (2) : a form in which food is given a decorative shape Spring

More information

C T M A S y m p o s i u m. Reality. WhereIdeas Become

C T M A S y m p o s i u m. Reality. WhereIdeas Become 2 0 0 5 C T M A S y m p o s i u m WhereIdeas Become April 19 & 20, 2005 Tacoma, Washington Reality Kyle Morris, P.E., Naval Undersea Warfare Center Keyport, WA Dennis Reiland, General Pattern Company Blaine,

More information

MEM23131A Evaluate rapid prototyping applications

MEM23131A Evaluate rapid prototyping applications MEM23131A Evaluate rapid prototyping applications Release: 1 MEM23131A Evaluate rapid prototyping applications Modification History Release 1 (MEM05v9). Unit Descriptor This unit of competency covers the

More information

Thermoplastic and Thermoset Processing Methods

Thermoplastic and Thermoset Processing Methods CIENCIA DE LOS POLÍMEROS Thermoplastic and Thermoset Processing Methods There are a variety of different processing methods used to convert polymers into finished products. Some include: Extrusion - This

More information

DESIGN AND MANUFACTURING OF THE INJECTION MOLD FOR METAL-INSERTED RUBBER PARTS USING CAD/CAM/CAE TECHNOLOGIES: A CASE STUDY OF THE ENGINE MOUNTING

DESIGN AND MANUFACTURING OF THE INJECTION MOLD FOR METAL-INSERTED RUBBER PARTS USING CAD/CAM/CAE TECHNOLOGIES: A CASE STUDY OF THE ENGINE MOUNTING Proceedings of IMECE2008 2008 ASME International Mechanical Engineering Congress and Exposition October 31-November 6, 2008, Boston, Massachusetts, USA IMECE2008-66843 ASME International Mechanical Engineering

More information

Plating & Surface Coatings

Plating & Surface Coatings Training Objective After watching the program and reviewing this printed material, the viewer will become familiar with the various plating and surface coating methods used in industry. Basic plating and

More information

METAL CASTING PROCESS

METAL CASTING PROCESS METAL CASTING PROCESS 1. Permanent Pattern a. Sand casting b. Shell molding 2. Expandable pattern. a. Investment Casting b. Expanded polystyrene process (full-mold) c. Permanent mold casting process 3.

More information

3D Printing and Structural Analysis: Is There an Alternative to FE Analysis for Quick Design Info & for FEM Validation?

3D Printing and Structural Analysis: Is There an Alternative to FE Analysis for Quick Design Info & for FEM Validation? Orange County Chapter 3D Printing and Structural Analysis: Is There an Alternative to FE Analysis for Quick Design Info & for FEM Validation? FW Palmieri, Ph.D. 3/24/2014 Copyright 2014 Raytheon Company.

More information

Rapid Prototyping T A R E K A. T U T U N J I

Rapid Prototyping T A R E K A. T U T U N J I Rapid Prototyping T A R E K A. T U T U N J I Prototype A prototype can be defined as a model that represents a product or system. This model is usually used for functionality testing and product visualization.

More information

April 26 th, Page 1. A Hitachi Group Company. Copyright 2016 All Rights Reserved

April 26 th, Page 1. A Hitachi Group Company. Copyright 2016 All Rights Reserved April 26 th, 2016 Page 1 About HTMF Key Information: AS 9100 & ISO 9001 Certified Primary NAICS Codes: 332710, 332999, 333511 Cage Code: 79N81 D&B: 969818025 Capability Statement: HI-TECH Machine & Fabrication

More information

Rapid Prototyping & Additive Manufacturing

Rapid Prototyping & Additive Manufacturing Discover The Magic Of Unlimited Design Sauber Aerodynamik AG I I 2016 Page 1 Your Advantages Discover the magic of rapid prototyping What is Rapid Prototyping? Rapid Prototyping (RP) is magical. In conventional

More information

Tech Transfer to Start-up and Manufacturing - Fabrication. Chris Moody

Tech Transfer to Start-up and Manufacturing - Fabrication. Chris Moody Tech Transfer to Start-up and Manufacturing - Fabrication Chris Moody Fabrication Incubators Business incubators can be just office space with business services and advice or they can provide early manufacturing

More information

PRECISION PROTOTYPING THE ROLE OF 3D PRINTED MOLDS IN THE INJECTION MOLDING INDUSTRY

PRECISION PROTOTYPING THE ROLE OF 3D PRINTED MOLDS IN THE INJECTION MOLDING INDUSTRY By Lior Zonder, Applications Team Leader Nadav Sella, Solutions Sales Manager, Global Field Operations Injection molding (IM) the process of injecting plastic material into a mold cavity where it cools

More information

RAPID PRODUCT DEVELOPMENT

RAPID PRODUCT DEVELOPMENT Rapid Product Development and Rapid Prototyping service American Engineering Group (AEG) offer rapid product development service, a rapid and more costeffective solution for manufacturing. Bringing new

More information

Protomold Overview and Rapid Injection Molding

Protomold Overview and Rapid Injection Molding Protomold Overview and Rapid Injection Molding Kevin Crystal Sr. Quality Engineer What is Injection Molding? Rapid Injection Molding 1) The hopper is loaded with the plastic stock material. 2) A heated

More information

THE USE OF THERMAL EXPANSION CORES FOR NON-AUTOCLAVE PROCESSING OF PRE-PREG MATERIALS

THE USE OF THERMAL EXPANSION CORES FOR NON-AUTOCLAVE PROCESSING OF PRE-PREG MATERIALS THE USE OF THERMAL EXPANSION CORES FOR NON-AUTOCLAVE PROCESSING OF PRE-PREG MATERIALS Presented by Mark Crouchen Rockwood Composites Ltd Tel 01626 240026 What is a Pre-preg? Pre-preg is a the name used

More information

3D Printed Injection Molding Tool ("PIMT") Guide. Objet Ltd.

3D Printed Injection Molding Tool (PIMT) Guide. Objet Ltd. 3D Printed Injection Molding Tool ("PIMT") Guide Objet Ltd. 2 Injection molding is a high speed, automated and versatile process that can produce high precision complex three dimensional parts from a fraction

More information

1.2 CASTING PROCESSES EXPENDABLE MOLD CASTING. Sand Casting

1.2 CASTING PROCESSES EXPENDABLE MOLD CASTING. Sand Casting Valery Marinov, Manufacturing Technology Metal Casting 5 1.2 CASTING PROCESSES Sand Casting EXPENDABLE MOLD CASTING In expendable mold casting, the mold is destroyed to remove the casting and a new mold

More information

ALUMINUM CASTING PROCESS COMPARISON CHARTS. Copyright 2002 Austin Group, LLC. All rights reserved.

ALUMINUM CASTING PROCESS COMPARISON CHARTS. Copyright 2002 Austin Group, LLC. All rights reserved. ALUMINUM CASTING COMPARISON CHARTS A Qualitative Comparison of Several Competing Processes for the Production of Aluminum Castings The following charts are intended to provide a relative guide to compare

More information

WHERE INNOVATION MEETS PRECISION

WHERE INNOVATION MEETS PRECISION WHERE INNOVATION MEETS PRECISION TWO COMPANIES ONE SOLUTION The Augustine Group of Companies are a multifaceted group of manufacturing companies which serve a broad array of end markets throughout the

More information

Processing of Non-Metals Prof. Dr. Inderdeep Singh Department of Mechanical and Industrial Engineering Indian Institute of Technology, Roorkee

Processing of Non-Metals Prof. Dr. Inderdeep Singh Department of Mechanical and Industrial Engineering Indian Institute of Technology, Roorkee Processing of Non-Metals Prof. Dr. Inderdeep Singh Department of Mechanical and Industrial Engineering Indian Institute of Technology, Roorkee Module - 1 Engineering Materials and Processing Lecture -

More information

PROCESSING OF VARIOUS MATERIALS

PROCESSING OF VARIOUS MATERIALS 4 PROCESSING OF VARIOUS MATERIALS CHAPTER CONTENTS 4.1 Shaping Processes for Polymers Polymers Manufacturing Processes for Polymers 4.2 Rubber Processing Technology Processing of rubber into finished good

More information

SENIOR DESIGN PROJECT DR. JOHN FRATER DR. WILLIAM ATHERTON THE RAPID SOLIDIFICATION PROCESS (RSP):

SENIOR DESIGN PROJECT DR. JOHN FRATER DR. WILLIAM ATHERTON THE RAPID SOLIDIFICATION PROCESS (RSP): SENIOR DESIGN PROJECT DR. JOHN FRATER DR. WILLIAM ATHERTON THE RAPID SOLIDIFICATION PROCESS (RSP): Its Theoretical Basis, and the Benefits it Offers the Manufacturing Industry Prepared By: Yaw Apatu Eric

More information

uv.eb West 2015 Dr. Mike J. Idacavage PL Industries A division of Esstech, Inc. March 10, 2015

uv.eb West 2015 Dr. Mike J. Idacavage PL Industries A division of Esstech, Inc. March 10, 2015 uv.eb West 2015 Dr. Mike J. Idacavage PL Industries A division of Esstech, Inc. March 10, 2015 Agenda Intro to 3D Printing Overview of 3D Printing Technology UV Curable 3D Printing Strength, Weaknesses,

More information

Two-Shot Silico e Thermoplastic Medical Molding

Two-Shot Silico e Thermoplastic Medical Molding Two-Shot Silico e Thermoplastic Medical Molding Author: Sarah J. Voss, Product Specialist, Medical Co-Authors: Mark Simon, Ph. D. Research & Development Manager Danny Ou, Ph D. Research & Development,

More information

DEFINITION. Casting can be defined as the act of forming an object in a mould

DEFINITION. Casting can be defined as the act of forming an object in a mould CASTING PROCEDURES DEFINITION Casting can be defined as the act of forming an object in a mould OBJECTIVES 1. To heat the alloy as quickly as possible to a completely molten condition. OBJECTIVES. 2. To

More information

Electrical Discharge Machining

Electrical Discharge Machining Training Objectives After watching the video and reviewing this printed material, the viewer will gain knowledge and understanding of electrical discharge machining, or EDM, principles and capabilities.

More information

Contents. Introduction. Case study 1 SLA/Wind Tunnel Model. Case study 2 SLA/Chess Set. Case study 3 Rapid Casting/Gearbox

Contents. Introduction. Case study 1 SLA/Wind Tunnel Model. Case study 2 SLA/Chess Set. Case study 3 Rapid Casting/Gearbox Rapid Prototyping techniques allow cost effective models and prototype parts to be produced in a few days. Contents Introduction Case study 1 SLA/Wind Tunnel Model Case study 2 SLA/Chess Set Case study

More information

Finite Element Thermal Analysis of Conformal Cooling Channels in Injection Moulding

Finite Element Thermal Analysis of Conformal Cooling Channels in Injection Moulding 5 th Australasian Congress on Applied Mechanics, ACAM 2007 10-12 December 2007, Brisbane, Australia Finite Element Thermal Analysis of Conformal Cooling Channels in Injection Moulding A.B.M. Saifullah

More information

The Prototyping Challenges with Micro Molding: A Comparative Study of Prototyping Methods for Micro Molding Applications

The Prototyping Challenges with Micro Molding: A Comparative Study of Prototyping Methods for Micro Molding Applications I. The Premise A lot has changed in the last 20+ years. Just two short decades ago our top speed personal computer processors were clocked at 386 MHz, hard drive space and RAM memory were still measured

More information

DIRECT METAL PRINTERS. Metal Additive Manufacturing with the ProX DMP Series

DIRECT METAL PRINTERS. Metal Additive Manufacturing with the ProX DMP Series DIRECT METAL PRINTERS Metal Additive Manufacturing with the ProX DMP Series Go Further with Direct Metal Printing UNLOCK YOUR PRODUCT S POTENTIAL With complete design freedom, direct metal 3D printed parts

More information

3D PRINTED INJECTION MOLDS

3D PRINTED INJECTION MOLDS 3D PRINTED INJECTION MOLDS CAN YOUR BUSINESS BENEFIT? MARK BASHOR 1 STRATASYS / COMPANY OVERVIEW WE ARE THE 3D PRINTING SOLUTIONS COMPANY 2 STRATASYS / COMPANY OVERVIEW FROM SYSTEMS TO SERVICE 3 STRATASYS

More information

Metal Injection Molded Parts

Metal Injection Molded Parts Metal Injection Molded Parts Metal Injection Molding (MIM) is a powder metallurgy process. he difference between MIM and conventional powder metallurgy is that in MIM, metal powder along with binders is

More information

Sinterstation. Pro Direct Metal SLM System

Sinterstation. Pro Direct Metal SLM System Sinterstation Pro Direct Metal SLM System Jim Dier SLS and SLM Systems, Upper Midwest 3D Systems, Inc. 18 July 2008 Introduction Product overview Systems Sinterstation Pro DM100 SLM System Sinterstation

More information

General environment. Basic structure of the machines. CAE DS Mould Design. Tampere University of Technology Tuula Höök

General environment. Basic structure of the machines. CAE DS Mould Design. Tampere University of Technology Tuula Höök General environment Tampere University of Technology Tuula Höök This chapter discusses injection molding and high pressure die casting machines. Most of the topics are important for the tool designers,

More information

Processing of Non-Metal Prof. Dr. Inderdeep Singh Department of Mechanical and Industrial Engineering Indian Institute of Technology, Roorkee

Processing of Non-Metal Prof. Dr. Inderdeep Singh Department of Mechanical and Industrial Engineering Indian Institute of Technology, Roorkee Processing of Non-Metal Prof. Dr. Inderdeep Singh Department of Mechanical and Industrial Engineering Indian Institute of Technology, Roorkee Module - 4 Plastics: Properties and Processing Lecture - 4

More information