Worldwide Advances in Rapid and High-Performance Tooling Conference

Presented by

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, phone 49 69 27 40 03 0, fax 49 69 27 40 03 40.

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.

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

Session 2
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.   

15:00   Improving Performance Using Direct Metal Deposition and Laminate Tooling
            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.