present a special conference titled
Worldwide
Advances in Rapid and
High-Performance Tooling
Date
and Time: Friday 6 December 2002, 9:30 – 17:00
Location: Exhibition Center Frankfurt, Hall 9.1, Room Logos
Organizer: DEMAT GmbH
Scientific Chairman: Terry Wohlers, Wohlers Associates, Inc.
Conference Language: English
Fee per Session: EUR 70. Includes
entrance into the conference and exhibition, technical papers, lunch,
GARPA reception and party, and valuable prizes.
Registration: Contact DEMAT GmbH (Frankfurt, Germany) at www.euromold.com,
phone 49 69 27 40 03 0, fax 49 69
27 40 03 40.
Description
This
special and intriguing one-day conference focuses on some of the most
important methods, applications, and technologies for rapid tooling, as
well as tooling that offer superior performance. The event features
world-class speakers that will share secrets and advice on the
unconventional methods of tooling that work well and those that do not.
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.
Program
9:30
Welcome: Dr. Eberhard Döring, DEMAT GmbH
Session 1
9:45
New Developments and Trends
Terry Wohlers, Wohlers Associates, Inc. (USA)
Industry
consultant Terry Wohlers will discuss the hottest developments and trends
in rapid
and high-performance tooling. The presentation will provide news and updates
on Arcam, Ford Sprayform, Optomec, ProMetal, RSP Tooling, and other
products, processes, and companies. Wohlers will also discuss tool design
software including Magics Tooling from Materialise and a development that
is underway at TNO Industrial Technology. Wohlers will help listeners sort
through the maze of options and understand which are most promising for
specific tooling applications.
10:30
Foundry
Tooling and Metal Castings in Days
Thomas
Krouth, Griffin Industries Corp. (USA)
Tom Krouth, an innovative leader in the casting field and president of
Griffin Industries, will present case studies from a variety of leading
companies. Krouth will discuss the following three approaches to using the
new ZCast process from Z Corporation: 1) production intent tooling, 2) direct pour, and 3)
shell pour. Production intent tooling is a new approach based on
printing cope and drag tooling using 3D printed parts that are infiltrated
with epoxy, and ZCast cores that are designed to solve short run, bridge
tooling problems. Direct
pour involves 3D printing a mold set, complete with gating and
venting, in the ZCast materials set, and then pouring the part. The shell
pour method is an approach in which shell inserts are printed and
traditional foundry methods are used to set the inserts in chemically
bonded sand. The gating and venting are added manually.
11:00 Break
11:30 Rapid Hybrid
Tooling in Vehicle Creation
Ralf
Kehrberger, DaimlerChrysler AG (Germany)
Today, as many emerging technologies are enhancing the efficiency of
product development and manufacturing, a major concern is to integrate
modern tooling methods into product creation. Among a company's business
units, each with specialized applications for rapid rooling, a clear
potential for far-reaching synergy is important. Hybrid tools may be the
answer to future product design and production processes developed
side-by-side in a digital environment. In particular, machines for fusing
metal powder materials, such as using Concept Laser's M3
Linear, is thought to be one solution for building complex and
fully dense metal tools or tool components. In vehicle creation,
applications such as plastic injection molding show the potential for
high-performance tooling. This promises an increased efficiency in both
product creation and manufacturing.
12:00 Multi-Functionality
of Tools and Products by Ultrasonic Consolidation
Neil
Calder, BAE Systems (England)
The
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.
12:30 Buffet Lunch
Session
3
14:00 Rapid
Tooling Using SLS LaserForm Technology
Ziad
Abou of CEP (France)
CEP
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.
14:30 DMLS
for Injection Molding and Die Casting Applications
Seppo
Syrjälä, Rapid Product Innovations (Finland)
Direct
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.
J.H.
Kostelni, Bontex
(USA)
Bontex
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.
15:30 Break
Session
4
16:00
Conformal
Heating and Cooling Channels for High-Performance Tooling
Philip
Dickens, Loughborough
University (England)
Polyurethane
(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.
16:30
Improving Tool Performance Using Conformal
Channels
Kenny
Dalgarno, University of Leeds (England)
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.
| 17:00 GARPA Party & Reception
Meet representatives from the Global Alliance of Rapid Prototyping Associations (GARPA) and win valuable gifts and prizes. |
 |
