and Time: Friday 6 December 2002, 9:30 – 17:00
Over the past few years, some methods of rapid and high-performance tooling have improved to the point where they now offer vital strategic benefits. Some of these methods enable users to embed channels that conform to the shape of mold or die cavities, thus improving production cycle time. Other methods reduce or eliminate the need for EDM (spark erosion), saving significant time and expense.
Tooling and Metal Castings in Days
of Tools and Products by Ultrasonic Consolidation
rapid manufacture of tools and products by additive processes enables
dissimilar materials to be placed under numerical control in specified
patterns and geometries. BAE’s Neil Calder will present a vision that
couples emerging materials processing capabilities with the requirements
for functionally graded and multifunction parts. In particular, he will
highlight the potential for exploiting Solidica’s Ultrasonic
Consolidation (UC) in this area. UC offers a low cost route for the
creation of multi-material integrated products with functionality in a
number of areas. This solid-state consolidation technology offers
solutions to unique engineering problems.
has used the Selective Laser Sintering (SLS) process to produce tooling
for four years. The company began with RapidSteel, then progressed to
RapidSteel 2, and subsequently to the stainless steel based LaserForm
ST-100 material. Abou will compare LaserForm to 3D Keltool and will give
examples of rapid tooling projects from 2002. Also, he will discuss the
economics (and profits) involved with SLS tooling. Finally, Abou will
explain the key to success in using SLS for rapid tooling.
for Injection Molding and Die Casting Applications
Metal Laser Sintering (DMLS) has been in commercial use at Rapid Product
Innovations Oy since 1995. During this seven-year period, hundreds of
tools have been produced for a range of purposes. The sintering technology
was initially used for the manufacture of inserts for injection molding
tools. After EOS launched the DirectSteel material in 1998, die casting tools
were produced successfully. The best results in mold production
have been reached by combining high speed milling with sintering. Milling
is used for some surfaces, while sintering is used to eliminate the need
for EDM (spark erosion). This “hybrid” tooling approach has proven to
be successful for many applications. The presentation will highlight
several interesting case studies.
develops advanced technologies and applies them to create value in
manufacturing components used in producing everyday products, such as
footwear. Bontex's development and use of Direct Metal Deposition (DMD)
from The POM Group and laminate tool fabrication for injection molds are
fundamental to creating value in lowering costs, improving quality, and
getting products to market faster. In this presentation, Kostelni will
bring focus to the practical applications of the technologies and will
share his company’s experiences with the integration of these
technologies in product design, prototyping, and production.
(PU) foam molded products are used for a variety of applications including
automotive, rail, and aerospace. A car may have 50 to 100 PU foam molded
products including seats, boot liners, and side impact cushions. PU foam
molded products are manufactured by mixing raw materials (a polyol and an
isocyanate) in a preheated tool. The heat from the tool acts as a catalyst
to cure the raw materials, which expand and fill the cavity. PU foam
molding tools are typically manufactured from aluminum by drilling
straight channels to supply heated fluid. Loughborough University has
produced laminated tools with conformal channels that more closely control
heat transfer, resulting in better quality parts and cavity filling that
is impossible any other way.
Improving Tool Performance Using Conformal
Dalgarno will report the results of studies designed to assess layer manufacturing processes that are capable of production quality injection and transfer mold tooling. The specific process considered is Selective Laser Sintering (SLS) from 3D Systems, along with its LaserForm stainless-based material. Tools produced with this process were used in industrial trials to assess productivity benefits arising from the use of conformal channels and to investigate tool wear. Cost models of the molding processes have been developed to investigate the economic case for the use of SLS tools. It was concluded that significant productivity benefits are available through the use of this tooling, and that the SLS process is economically competitive compared to existing methods of production tooling.