Beyond Stereolithography Presented by: Paul Armstrong

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Text of Beyond Stereolithography Presented by: Paul Armstrong

  • Beyond StereolithographyPresented by: Paul Armstrong

  • ConceptsTime CompressionCost effective new product introductionRapid PrototypingRapid ToolingFunctional Plastic and Metal PrototypesMarriage of CAD & RP technology with crafts-based traditional patternmaking skills

  • If everything is under control, youre probably not going fast enoughMario Andretti

  • Why Use Prototypes?Fit and Function TestingDesign Verification and RefinementMarket Analysis and FundingAid for designing production tooling and fixtures

  • Benefits of RPQuick production of prototype or modelModel produced from designers databaseProvides excellent pattern for:Aluminum castings via sand or plaster-moldPlastic parts in thermoplastic resins or urethanes

  • Machined Aluminum CastingsPlaster MoldRPMPrecision Air-set SandGraphite Mold

  • Benefits of RPM CastingAluminum, zinc or magnesium parts in 1-5 weeksDie Cast Prototyping Simulates die casting for appearance and physical propertiesSoft tooling allows for ease of geometry modificationRelatively low cost- Magnitude of ten rule of thumb

  • Benefits of RPMCan be production process for projects that cant justify hard toolingBridge tooling and tooling insuranceReplace lost production toolsExcellent surface finishesAccommodates complex geometry with undercutsThin wall sections with excellent weight to strength ratio0.080 wall typical 0.020 wall possible

  • CastForm Parts in 1 Week1 SLS MODEL1 ALUMINUM CASTING

  • Precision Sand Casting

  • Benefits of Precision Sand CastingAluminum cast parts in 2-5 weeksExcellent surface finish and overall casting appearance compared with other sand processesSuperior metallurgical properties

  • Cast Parts in 2 weeks via RPM or SandDay 1:file transfer and interpretationengineering review and prep part for processDays 1-2:creation of master patternDays 3-5:creation of foundry toolingDay 6:pour & bake moldsDay 7:pour castingsDays 8-10:secondary operations and qualify castings

  • Benefits of Graphite MoldingAluminum, zinc or magnesium parts in 3- 5 weeksSemi-permanent mold will make hundreds of parts from one toolIdeal for 100-2000 partsShort run productionBridge from prototype process to productionAble to cast spec die-cast alloys: 380, 390More accurate test results for tensile, yield, hardness

  • Tensile Strength- 380 T6

  • Rapid Injection Molding using Cast Tooling

  • What is Kirksite?Zinc-aluminum alloy94% Zn, 6% AL725 F melting pointCastable, machinable, weldableZinc is used to enhance tool lifeKirksite molds have been around for fifty yearsSLA/RP technology unlocked real potential

  • Benefits of Rapid Injection MoldingPrototypes in production thermoplastic resins in a 1-4 weeksAllows for full functional testingRelatively low cost tooling made from SLA masterBridge or production toolingMolds can run thousands of partsCast tooling can be used for many plastic processes

  • Tooling for Rapid Injection MoldingPrototyping/ Design Verification/Bridge ToolCast KirksiteSintered SteelMachined AluminumProductionCast KirksiteMachined aluminumSintered SteelMachined Steel

  • Limitations of Cast ToolingTolerancingTight tolerance CTF dimensions can be machined into mold or partsCosmeticsAppearance critical areas can be enhanced thru mold finishing Upgrade cooling and ejection

    Tool lifeMolds can run thousands of parts depending on materialDupilcate tool easily made from masterMaterialsGlass filled - insert in high wear areasMaterial temp< 725 F

  • Cast Tooling vs. Cut ALCheaper and quickerTooling upgradeable after prototype runComplex 3D geometryCompound curvesAngular shapesSpeeds design refinement cycleCTF quality requirement

  • RIM- Reaction Injection MoldingPolyurethane molded parts in 2-5 weeksExcellent flowability and processing allows for molding of:Complex shapesSoft and sharp detailThick and thin sectionsOpenings, ribs and louversFoamed polyurethanes are natural thermal and acoustic insulators

  • RIM BenefitsLow internal mold pressuresLow cost tooling allows for ease of geometry modificationSuperior cosmetic appearance for visible componentsSuperb encapsulation capabilityReduction in assembly operations with part consolidation

  • When to use RIMHousings, bezels, chassis, bases, doors, speaker enclosuresVisually critical applicationsLarge plastic partsEncapsulation requirementsInsulation requirements

  • Types of RIM toolingSilicone rubber - handful of partsEpoxy resin - up to 100 pcsSpray metal - several hundred pcsCast toolingMachined aluminumMachined steel

  • Thank You for ComingArmstrong Mold Corporation 6910 Manlius Center Road East Syracuse, New York 13057-9597 Phone: (315) 437-1517Email: sales@armstrongmold.com Web: www.armstrongmold.com