Professional Documents
Culture Documents
Guided By
Dr. K.G.Dave
Assistant Professor
Dept. of Mech. Eng.,
LDCE, Ahmedabad
Presented By
Parikh Ravi Rajesh Kumar
Enroll. No140280708008
4th Sem. ME CAD/CAM
Dept. of Mech. Eng.,
LDCE, Ahmedabad
Rapid prototyping
Rapid Prototyping (RP) techniques are methods that allow
designers to produce physical prototypes quickly.
It consists of various manufacturing processes by which a
solid physical model of part is made directly from 3D CAD
model data without any special tooling.
Rapid tooling
Rapid Tooling refers to mould cavities that are either directly or
indirectly fabricated using Rapid Prototyping techniques.
These are primarily used to create multiple prototypes. Rapid
prototyping techniques are not economical when more than one
prototype needs to built for the same component.
Soft Tooling: Silicone molds and the urethane process are used when a lower
volume of parts is needed (1-100). This is because the tooling
and piece price is more economical for lower quantities. On
average, silicone tools usually cost in the hundreds to
thousands of dollars, pending on the part geometry.
Siliconemolds can be used for prototype, bridge and
production of low volumes from one part to hundreds of parts.
Most silicone molds are good for about 25 shots per cavity.
Silicone molds are typically injected with material that is
manually gravity fed through a tube. Pending on the type of
material, it cantake anywhere between 1-24 hours to cure.
Once the parts within the mold cure, the molds aremanually
opened, and any necessary finishing is done by hand.
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Soft Tooling:-
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Hard Tooling:
Steel/aluminum tools areused for the injection
molding process for prototype or bridge, but these
tools are mostly used for high volume production
(100s-100,000s).
Steel/aluminum tools typically range in price from
thousands to tens of thousands of dollars. And pending
on the material and part geometry, the tool life can
range from thousands to millions of parts.
Steel/aluminum tools are injected with material from
an injection mold machine. The machine injects mold
into the mold with less man-power when compared to
silicone molds. The curing of material will take
between a few seconds to a few minutes, thus yielding
more parts much quicker than silicone tools.
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Hard Tooling:
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Hard Tooling
Higher Cost Tooling
Lower Piece Part Cost
NO Design Flexibility
Repeatability
Longer Lead Time Due To
Tooling Lead Time
Process For High Volumes
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Epoxy tooling:
Its also known as Composite Tooling
Like silicone rubber tooling, epoxy-based composite tooling
requires a master pattern.
This pattern is created by RP process.
The pattern is finished and then embedded in a parting line
block to create the parting line of the mould.
Metal inserts are placed in areas where the epoxy is unlikely to
withstand the pressures of the injection-moulding process.
Epoxy is then cast against the pattern and parting line block
combination to create the first side of the tool.
Once the epoxy has cured, the assembly is inverted, and the
parting line is removed, leaving the pattern embedded in the
first side of the tool.
The second side of the tool is then cast against the first.
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Epoxy tooling:
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RP Model
Finished Model
Metal spraying
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RSP Tooling
RSP stands for Rapid Solidification Process
We create a plastic model using SLA
And then we make moulds with either by epoxy tooling or
spray metal onto it
But most of the cases, ceramics are used
Whats significant in that is that we atomize the metal down to
as small as 5 microns.
When the metal hits the ceramic, because of the small size of
the droplets, they freeze very quickly, thus the rapid
solidification.
This process results in extremely fine grain structure and the
alloys generally stay in solution and there is very little internal
stress
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RSP Tooling
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Cast Kirksite
Kirksite is a zinc-aluminum alloy with excellent wear
resistance. (94 % Zn, 6% Al) with a melting point of 3855C)
The process for making cast kirksite tooling begins much like
the process for epoxy-based composite tooling, except that two
additional reversals are required to permit the creation of
tooling in a more durable material
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3D Keltool
3D Keltool is a powder metal process used to make injectionmould inserts and other durable tooling from master patterns
It is very similar spray metal tooling
Keltool was originally developed by 3M in 1976 and was sold
and further developed by Keltool Inc. In 1996, 3D Systems
purchased the technology from Keltool Inc. and renamed it 3D
Keltool
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3D Keltool
This process requires a master pattern, typically an SLA
model, that can be used to develop a silicone mould that
will then be used to produce the Keltool mould.
The Keltool mould is then processed with a copper
infiltration and sintered to increase its strength and cure
the mould.
The finished Keltool part has the hardness of a A6 Tool
Steel and can be machined like a traditional hard tool.
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Thank
you
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