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V.VISHNUTEJA

NFTDC ID # 55025

BY

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1. Quick Review of RP Process

2. Basics of Rapid tooling & the process

3. Tooling Schemes

4. Direct Tooling Techniques

5. Indirect Tooling Techniques

6. Merits & Applications

7. Future Scope

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Quick Review of RP Process:

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Rapid Tooling Process :

Rapid Tooling is a general terminology for using a technological

process to rapidly produce mold inserts for injection molding of

plastics and casting of materials.

The Process : Transferring non-functional models constructed

form the range of RP Techniques into a functional prototype part.

Materials used are

ABS Cycolac

Polycarbonate Lexan

Polycarbonate /ABS Cycoloy

Nylon Zytel

Ployprylene

polyethylene

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Tooling Schemes:

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Enables the production of inserts capable ofsurviving from a few

dozen to tens of thousands of cycles and represent good

alternatives to traditional molding techniques.

Classfied into two as Firm tooling ( Bridge Tooling) which includes

less expensive methods with shorter lead times that are

appropriate for tool validation and Hard Tooling which performs

above operation with greater cost and higher lead time.

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2. Laminate tooling : Uses LOM machine to build molds based on

advanced materials like epoxy or ceramics withstanding abnormal operating

conditions.

3. Sandform tooling : Uses SLS technique and produces cores used in low

pressure sand casting.

4. EOS Direct Tool Process : Used for rapid production of complex inserts ,

the surfaces of which can not be machined directly.

5. Direct metal tooling using 3D printing : Build tooling inserts in range of

materials including Stainless steel ,tungsten and tungsten carbide.

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Indirect Tooling :

Alternates to traditional mould-making techniques and necessitate a

minimum of one intermediate replication process.

Intended as pre-production tooling and produce large drafting angles

,simpler part shapes and lower mechanical-thermal specifications.

1. Room Temperature Vulcanizing :

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Epoxy Tooling :

moulds for prototype plastic

injection ,castings, compression

moulds

Ceramic Tooling:

Used in plastic processing ,metal

forming and metal casting.

Amount of water required has to becontrolled to avoid excess shrinkage in

the material sets.

Spin Casting:

Spin casting moulds for metal parts

are made up of heat-vulcanized

rubber.

Involves injecting a material into amould that rotates at high speed.

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INVESTMENT CASTING:

Wax patterns are employed to

define

Shape and are then melted away. SL

is used to create the pattern.

Usually of two types : Shell

investment casting and solid flask

investment casting

SAND CASTING:

Employed for production of large

metal

Parts with low surface quality.

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Metal Spray :

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APPLICATIONS :

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ADVANTAGES :

The potential to develop better quality products.

Reduces total production time and inaccuracies caused by intermediate

replication stages.

Provides real opportunities to cut overall costs of a product launch and

considerably increase the chances of its commercial success.

The high cost of labour and short supply of skilled patternmakers can be

overcome

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FUTURE SCOPE & CHALLENGES :

Use of IGES ,HPGL ,STEP & VRML instead of STL

CAD tools for Micro structured objects

Development of Voxel based and FE based methods for micro

structured objects.

Production of materially graded structures

Productivity/ Cost of RP Materials

Materials

Process Planning

RP data formats and design tools

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