Team 5Alexander ClaytonAndrew Robinson

Kerrie NobleMarissa Carlin

Scott Hillen

RAPID TOOLING

ContentsOverviewBackgroundExamples of rapid tooling productsRapid tooling process

Direct routesIndirect routes

AdvantagesDisadvantagesFuture developments

What is Rapid ToolingRapid tooling is a term used to describe a process which either uses a rapid prototyping model as a

pattern to create a mould quickly or uses the rapid prototyping process directly to fabricate a tool for a limited volume of prototypes.

The most common rapid tooling methods are

KeltoolSprayed metal toolingACES

Investment castingSelective laser

sinteringStereolithography

BackgroundThe term Rapid Tooling was introduced in the

mid 1990sUsed to describe any method that would

replicate an injection mould to manufacture a physical plastic or metal part

In 1989 the program tomorrows world on the BBC showed the first stereolithography machines to be installed at BAe systems

1992 Tim Plunket, managing director of Formation Limited, attempted to make a company from the new technology of stereolithography

Examples of Rapid Tooling Products

(a) (b)

(a) Example of a porous metal mould made by rapid tooling http://www.physorg.com/news176456761.html (b) Shows an example of a plaster mould made by rapid tooling http://www.ultracast.com/mold-production.html

Examples of Rapid Tooling Products

(a) (b)

(a) An example of a case mould developed through rapid tooling http://www.alibaba.com/product-gs/311652056/CD_container_mould_dvd_case_mould.html (b) Shows an example of a sand casting mould made by rapid tooling http://www.objet.com/Misc/_Pages/Application_Notes_Left_Pane/Sand_Casting_Applications/

Rapid Tooling ProcessesRapid tooling processes use CAD/CAM

techniques to make tools and moulds for product assessment, short production runs and full production

Development cycles are shortened considerable and more economic

RT Process ClassificationRapid tooling is classified in two different categories

Direct routes – uses the CAD file to produce the tool in the final material

Indirect routes – uses a rapid prototyping model as a master pattern or case to make the moulds by established, more traditional, routes

Indirect RoutesRapid prototyping moulds can be used as the master models for several applications such as;

Silicone tooling to make wax models for investment casting or cast plastic partsPorous plastic moulds for pressure casting ceramicsCase moulds for bench castingPatterns for sand casting metalsWax rapid prototyping models for lost wax investment casting

Rapid Tooling for Investment Casting

1. Pattern Creation

2. Tree Assembly

4. Fill with investment

3. Insert into flask

5. Wax melt-out6. Fill mould with metal

7. Water-jet 8. Finish

Simplest method of applying rapid-prototyping operations to other manufacturing processes.

Rapid Tooling for Investment CastingRapid-Prototyping OperationStereolithography

• Used to create the pattern.• Photopolymers are cured using UV light to build layers in a

component.• For investment casting the polymer must be able to melt

and burn from the ceramic mould.

Invisalign Orthodontic AlignersThese aligners are manufactured using a combination of rapid tooling and thermoforming.They are an alternative to conventional orthodontic braces.

Rapid Tooling In Action

Polymer impression of patient’s teeth

Aligner is produced by thermoforming a transparent plastic sheet against the

model

Model is produced on

stereolithography machine of desired

tooth profiles

Computer modelling used produce CAD representations of

desired tooth profiles

Patient uses aligner for two weeks

Patient completes treatment

Injection Moulding is used in rapid tooling to produce moulds or mould inserts.

A CAD model is produced which can easily be edited. A common use of this technique is producing moulds for the slip

casting of ceramics.

Rapid Tooling and Injection Moulding

Injection

Moulded

product

Mould tool

created

using the

mould insert

Slip poured into mould

Slip drained from mould

to attain unifor

m thickn

ess

Removal of exces

s materi

al from

drainage site

Finished

product

ready to be fired

Rapid Tooling and RTV MouldingRoom-temperature Vulcanising (RTV) MouldingThe vulcanisation process uses a mixture of a polymer and a curing agent to change the state of the polymer by forming crosslinking bonds between molecules.Can be performed by preparing a pattern of a part by any rapid prototyping technology.RTV rubber is poured over the pattern and allowed to set. The mould is then used for injection moulding.One of the main disadvantages of using this type of rapid tooling is that the mould has a lesser mould life components within the rubber cause progressive damage.Limited to as few as 25 parts.

Keltool ProcessKeltool process starts by rapid prototyping a

rubber mould, which is then used to cast a steel powder and polymer binder mixture which is left to cure into a green state.

Once cured, it is then fired, and copper is infiltrated into the mould, resulting in a tool approx. 70%steel 30% copper.

This mould can then be polished or machined to increase surface finish and good tolerances although finishing is normally not required.

KeltoolKeltool Process created over 25 years ago by 3MProcess provides great accuracy and surface finish,

made primarily as a steel toolCan be used to create accurate mouldsMould life can range from 100,000 to 10,000,000

partsMould tools have limited size of volume, 150mm

cubedCompanies sometimes join two keltool moulds

together to increase mould tool size.Moulds are strong enough to withstand typical

injection mould temperatures in use

ACES (Acetal Clear Epoxy Solid)ACES mould tool parts can be used as inserts in a

standard injection moulding machine, easing material handling and integration to existing processes, as well as simplifying logistical measures.

Mould created using Stereolithography method, providing cavity on underside of mould. Two mould halves put together which is then filled with epoxy, ceramics, low melt metals or thermoplastics

Has a low tool life of 10 – 100 parts, with the tool having a dynamic failure, gradually degrading with each use.

Sprayed-metal ToolingRapid prototypying is used initially to create

the baseplate and part pattern with alignment tabs for the tool part. The base pattern must be hand finished to ensure the mould has the best quality to the specification required. This base is then coated using a zinc-aluminium alloy. This alloy coating and base are placed within a flask or tank which is then filled with an aluminium powder-filled epoxy. Once cured, the baseplate and pattern are removed and a second mould half is created for injection moulding, completing the mould tool.

Sprayed-metal Tooling• The mould tool is process dependant,

so can be used between 100-100,000 uses, as low pressure processes yield a greater tool lifespan.

Direct RoutesThe CAD file is used directly to produce the part without need for further operationsCan be used for;Selective Laser SinteringProduces porous metal moulds by CAD/CAMPlaster moulds made by CNC machining3D printingUses a wide variety of material – steel, copper polyamide etc.

Selective Laser SinteringThis method was introduced in 1999. It produces plastic parts, of increasing size for a growing number of applications.

Selective Laser SinteringUsed in every stage of the product

development cycleOne shot modelsFunctional test partsSmall production series

Series of 50 to 100 pieces or more

Engine block built on the EOSINT P700 machine with a build volume of 700x380x580 mm

Fused Deposition ModellingThis process fulfils the growing demand for functional models. Constructs three-dimensional objects from digital CAD dataLayers - +/- 0.127 - 0.254 mm thickness

FDM Center at Materialise HQ in Leuven

Laminated Object ManufacturingThe first commercial LOM system was shipped in 1991Produced in layers of thickness of typically 0.002-0.020 in Solid sheets of materialThermoplastic material usedApplications;

Form/fit testingLess detailed partsRapid tooling patterns

Rapid Tooling Equipment

(a)

(a) A picture showing a stereolithography machine in operation http://www.rtejournal.de/ausgabe4/index_html/1163/ (b) A selective Laser Sintering machine http://www.directindustry.com

(b)

Rapid Tooling Equipment

(a)

(a) Vacuum casting Prototyping machine http://www.directindustry.com (b) The latest development in Rapid tooling http://www.ferret.com.au/c/Industrial-Laser-Services/New-rapid-tooling-technology-Lasercusing-n689214

(b)

A New Rapid Tooling Process1. A three-dimensional computer model of the mould

is designed on the computer2. A plastic pattern with complementary shape to the

mould is fabricated using a RP process, such as Stereolithography

3. A thin metal layer is deposited onto the cavity side of the plastic pattern using an electro-chemical process to form a metal shell. Then, the metal shell is separated from the plastic pattern

4. Metal ribs are added to the back of the metal shell to increase the strength of the metal shell

5. The backside of the mould is sealed to prevent leakage of the metal powder. The tool is finished and ready for moulding operations

Shorter lead timesLow cost Environmentally friendly as the metal powder used in

the backing is fully recyclable

A New Rapid Tooling Process

http://www.intechopen.com/articles/show/title/a_new_rapid_tooling_process

Advantages-Reduced manufacturing time-much less expensive-Effective communication-decreases development time-removal of redundant features-early viewing of the product-early market testing-early testing (assembly, functional)

Disadvantagesshorter tool life-less accurate tolerances-not suitable for large sized applications-fail in product replication-cost is debatable-lacks an obvious stopping point-Usually does not produce reusable batch

code

Future Developmentstooling will become fasterreduced costreduced development timemore accurate (product testing will be

more accurate to the testing of a final completed product)

faster market testingproducts can be optimised and released

quicker

Companies/Marketing

Worldwide Market by Application

Worldwide Market Trend

According to a report from manufacturing consultancy Wohlers Associates, demand for products and services from the rapid manufacturing industry has been relatively strong for most of the technology’s 22-year history.  Also, a report from Frost & Sullivan found that the rapid prototyping and rapid tooling market earned revenues of $300 million in 2006, but total worldwide revenue is forecast to reach $859.4 million in 2013.

SummaryA process which uses rapid prototyping in the

fabrication of toolsIntroduced in the mid 1990sCommonly used to create moulds from various

materialsIndirect routes

Rapid Tooling for Investment CastingStereolithographyRapid Tooling for Injection MouldingRTV MouldingKeltoolACESSprayed Metal Tooling

SummaryDirect routes

Fused Deposition ModellingLaminated Object ManufacturingSelective Laser Sintering

Produced by many forms of rapid prototyping technology

Becoming more popular with industry, interest is continuously growing

Speeding-up the manufacturing process