1. Beyond Stereolithography
Presented by: Paul Armstrong

2. Concepts Time Compression Cost effective new product introduction
Rapid Prototyping
Rapid Tooling
Functional Plastic and Metal Prototypes
Marriage of CAD & RP technology with crafts-based traditional patternmaking skills

3. “ If everything is under control, you’re probably not going fast enough”
Mario Andretti

6. Why Use Prototypes? Fit and Function Testing
Design Verification and Refinement
Market Analysis and Funding
Aid for designing production tooling and fixtures

7. Benefits of RP Quick production of prototype or model
Model produced from designer’s database
Provides excellent pattern for:
Aluminum castings via sand or plaster-mold
Plastic parts in thermoplastic resins or urethanes

10. Machined Aluminum Castings
Plaster Mold–RPM
Precision Air-set Sand
Graphite Mold

11. Benefits of RPM Casting
Aluminum, zinc or magnesium parts in 1-5 weeks
Die Cast Prototyping
Simulates die casting for appearance and physical properties
Soft tooling allows for ease of geometry modification
Relatively low cost- Magnitude of ten rule of thumb

12. Benefits of RPM
Can be production process for projects that can’t justify hard tooling
Bridge tooling and tooling insurance
Replace lost production tools
Excellent surface finishes
Accommodates complex geometry with undercuts
Thin wall sections with excellent weight to strength ratio
0.080” wall typical ” wall possible

13. CastForm – Parts in 1 Week
1 SLS MODEL
1 ALUMINUM CASTING

19. Precision Sand Casting

20. Benefits of Precision Sand Casting
Aluminum cast parts in 2-5 weeks
Excellent surface finish and overall casting appearance compared with other sand processes
Superior metallurgical properties

22. Cast Parts in 2 weeks via RPM or Sand
Day 1: file transfer and interpretation
engineering review and prep part for process
Days 1-2: creation of master pattern
Days 3-5: creation of foundry tooling
Day 6: pour & bake molds
Day 7: pour castings
Days 8-10:secondary operations and qualify castings

23. Benefits of Graphite Molding
Aluminum, zinc or magnesium parts in 3- 5 weeks
Semi-permanent mold will make hundreds of parts from one tool
Ideal for parts
Short run production
Bridge from prototype process to production
Able to cast spec die-cast alloys: 380, 390
More accurate test results for tensile, yield, hardness

24. Tensile Strength- 380 T6

25. Rapid Injection Molding using Cast Tooling

26. What is Kirksite? Zinc-aluminum alloy Castable, machinable, weldable
94% Zn, 6% AL
725° F melting point
Castable, machinable, weldable
Zinc is used to enhance tool life
Kirksite molds have been around for fifty years
SLA/RP technology unlocked real potential

27. Benefits of Rapid Injection Molding
Prototypes in production thermoplastic resins in a 1-4 weeks
Allows for full functional testing
Relatively low cost tooling made from SLA master
Bridge or production tooling
Molds can run thousands of parts
Cast tooling can be used for many plastic processes

28. Tooling for Rapid Injection Molding
Prototyping/ Design Verification/Bridge Tool
Cast Kirksite
Sintered Steel
Machined Aluminum
Production
Machined aluminum
Machined Steel

29. Limitations of Cast Tooling
Tolerancing
Tight tolerance CTF dimensions can be machined into mold or parts
Cosmetics
Appearance critical areas can be enhanced thru mold finishing
Upgrade cooling and ejection
Tool life
Molds can run thousands of parts depending on material
Dupilcate tool easily made from master
Materials
Glass filled - insert in high wear areas
Material temp< 725° F

30. Cast Tooling vs. Cut AL Cheaper and quicker
Tooling upgradeable after prototype run
Complex 3D geometry
Compound curves
Angular shapes
Speeds design refinement cycle
CTF quality requirement

38. RIM- Reaction Injection Molding
Polyurethane molded parts in 2-5 weeks
Excellent flowability and processing allows for molding of:
Complex shapes
Soft and sharp detail
Thick and thin sections
Openings, ribs and louvers
Foamed polyurethanes are natural thermal and acoustic insulators

39. RIM Benefits Low internal mold pressures
Low cost tooling allows for ease of geometry modification
Superior cosmetic appearance for visible components
Superb encapsulation capability
Reduction in assembly operations with part consolidation

40. When to use RIM
Housings, bezels, chassis, bases, doors, speaker enclosures
Visually critical applications
Large plastic parts
Encapsulation requirements
Insulation requirements

41. Types of RIM tooling Silicone rubber - handful of parts
Epoxy resin - up to 100 pcs
Spray metal - several hundred pcs
Cast tooling
Machined aluminum
Machined steel

46. Thank You for Coming
Armstrong Mold Corporation 6910 Manlius Center Road East Syracuse, New York Phone: (315)
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