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Training Objective
After watching the program and reviewing this printed material, the viewer will understand the principles of
rapid tooling design and processes.
Indirect tooling
Direct tooling
Indirect tooling incorporates pattern-based methods where the tool is cast from a rapid prototype that depicts
the part to be molded.
Direct tooling is a method where the mold, inserts, or other components are made directly by a rapid
prototyping machine.
Rapid prototyping, which is also called additive fabrication, additive manufacturing, and freeform fabrication,
grows physical objects directly from 3D CAD data by bonding layers of material. The process is particularly
suited to prototype mold creation. The additive nature of the process allows intricate details and complex
shapes to be manufactured with little effort and no impact on time or cost. Also, much of the process is
completed without direct labor or a machine operator in attendance.
There are numerous rapid prototyping technologies used today including:
Stereolithography
Laser sintering
Fused deposition modeling
Various 3D printing processes
Although most rapid prototyping technologies can be used for indirect, pattern-based rapid tooling, the bulk
of the direct tooling work uses a metal-based technology such as direct-metal laser-sintering, selective laser
melting or laser cusing.
Indirect Rapid Tooling Processes
Indirect rapid tooling processes produce molds by forming them from a pattern. A common example of this
technique is RTV, or room temperature vulcanized rubber molding. Typically, the pattern used to produce
this type of indirect rapid tooling is constructed using a rapid prototyping machine.
Following the patterns construction, it is postprocessed to prepare it for mold creation. Once post-processed,
development of the first mold half typically begins by securing the pattern in oil-based clay, or other building
materials, and constructing the parting line.
Fundamentals of Tool Design Study Guide, DV08PUB3
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These additive processes produce tools made of stainless steel, cobalt, chromium, maraging steel, titanium,
and alloy blends.
Additionally, some companies have found success using stereolithography to create composite-plastic mold
inserts using resins such as the ceramic filled nanotool to produce small, short-run molds for injection
molding.
The basic, four-step process for constructing injection molds with rapid tooling techniques is the same as that
when machining a mold:
1.
2.
3.
4.
Tool design
Component building
Tool assembly
Injection molding
Tool design involves determining what components are to be rapid tooled or machined. This includes the
design of the tool inserts and the pockets in which they will seat in the mold core, cavity, or base. Other
design factors include draft angles, gating, venting, and reinforcement ribs.
Component building includes the simultaneous machining of mold elements while rapid prototyping of the
mold inserts is taking place. Once rapid prototyping is complete, the inserts are post-processed.
For nanotool inserts, post-processing includes parts washing, support removal and ultraviolet curing. For the
DMLS and SLM processes, this includes removal of supports and any excess metal powder. While the build
platform may be cut away from the metal insert, it is often included as an integral mold element.
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2.
A direct rapid tooling method well suited for small, short-run mold inserts is:
a. RTV
b. stereolithography
c. direct metal laser sintering
d. selective laser melting
3.
4.
5.
6.
A
a.
b.
c.
d.
7.
8.
9.
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c
b
c
d
a
d
d
a
b
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