APPLYING RAPID TOOLING FOR INJECTION MOLDING & DIE CASTING From a RT users perspective

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APPLYING RAPID TOOLING

FOR INJECTION MOLDING &

DIE CASTING

From a RT users perspective

Glenn Anderson

Senior Engineer, Research and Development Southco, Inc.

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Overview

1. Setting Expectations

2. Planning for Failures

3. Project Specification

4. Tooling

Requirements

5. RT Selection

6. CAD Preparation

7. Ordering Rapid

Tooling

8. Rapid Tool Finishing

9. Process Set-up and

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Setting Expectations for RT

• Communications

– Design changes in part or tooling (are any expected?) – Supplier: if delivery date slips

• Part Quality

– Dimensional control

– Surface finish – aesthetics

– Mechanical properties – relates to end part molding process parameters

• Tooling

– Durability

– Ease of repair, design changes – Processing performance capability

• Processing

– Raw Material – supplied by customer or supplier

– Tool Failure (removing stuck parts, part to tool material compatibility) – Cycle time

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Example of Rapid Tooling:

Spin Casting: Zinc in Rubber Tooling

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Planning for Failures

• Completion of paperwork and issuing PO – Terms of supplier

– Are 3D files complete and error free?

• Queue time & fabrication at RT supplier – RT manufacture process

– Customer priority

• Delivery of parts to customers deadline – Tool failure

– Shipping time through Customs (off shore purchase) – Secondary operations

• Tool finishing – texture, coating, etc. • Part processing

– Raw material availability – Damaged tool

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Project Specification

• Time Scale & Budget

– Allowance for quoting activity

– Use of 3D printed RP parts for quoting activity • saves money and time

– Buy: parts, mold cavities, mold base insert, or complete tool

• Quality

– Part design requirements: tolerance, cosmetic, texture, mechanical properties

– Tooling requirements – RT specification

• Quantity & Expected Life of Tooling

• Multiple tool planning-quick response / next

generation.

– incomplete impression for shortened response, revise part for next process step

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Tooling Requirements

• Part Requirement

– Concept

– Functional

– Pre-production, production like(Tool Life) – Production

• Tool material characteristics

• Any concern for future production mold

• Part material

– Compatibility with RT materials

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Rapid Tool Selection

• Direct RT Processes

– Direct Metal Processes

• Precision Optical Manufacturing DMD, Optomec LENS, …

– CNC Machining - traditional or high speed • Aluminum, tool steel, …

• Indirect RT Processes

– SLS Laserform ST100, Direct AIM(SLA), 3D Keltool,

investment cast, cast epoxy, Cast steel, spray metal, RTV rubber for spin casting, nickel shell, …

• Hybrid-mixed RT process.

– e.g. CNC P20 Cavity & SLS Laserform ST100 core with conformal cooling

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Nickel Plate Shell Spray Metal Steel SLS Rapid-Steel 2.0 Aluminum Filled Epoxy SLS Copper Duraform CNC QC7 Aluminum

RAPID TOOL TEST

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CNC P20 Steel Investment Cast H-13 Steel SLS Rapid-Steel 2.0 SLS Laserform ST100

RAPID TOOL TEST

-

Zinc Die Casting

POM DMD H13 Steel

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Ordering Rapid Tooling

• Non-technical issues that can affect project delivery – Is a cash deposit required with PO to start?

• Do they accept credit cards for tooling purchase?

– Is queue time included in the delivery quotation?

• Definition: Delivery time starts with issue of PO and ends with molded parts or delivery of tooling.

• Is the part design complete?

• What 3D CAD file type is preferred by supplier?

– Native CAD System (e.g. SDRC, Pro-E, etc.), IGES, STEP, STL, Other. What CAD file type will accelerate process?

• Send 3D RP part, CAD file & 2D drawing with PO or design changes!

– 2D drawing should have critical dimensions and tolerance requirements outside of RT process

• Inclusion of supplier and supply chain in design change

procedure. (keeps all involved, informed) Who owns the tool? Can it be brought in house after parts are run?

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3D CAD Preparation

• Part

– Parting line, witness lines, draft, ejector pin locations – Apply material shrink factors to determine allowances

• Tool Design (are hand loaded inserts required?)

– Additional shrink requirements from tool fabrication?

– Finish stock allowances

– Tool core/cavity registration features, ejection system, cores and slides, sprue, runner, gate, vents, overflows. Clamp

height of tool. – Cooling

– Use of analytical methods to design & optimize performance • MoldFlow® for plastic injection molds

• Corner radii allowance for cutting.

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Rapid Tool Fit and Finishing

• CNC Milling, EDM (sinker or wire), Grinding

– Tool Material – magnetic or non-magnetic

• Hand work, polishing

• Texturing and/or Engraving

– (adds 1 week, minimum, to process)

– In some transfer processes,, texture can be applied on master pattern and transferred into tool.

• Plating or hard coating

– (adds 1 week, minimum, to process)

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Zn Die Cast Rapid Tool

Note: Epoxy filler on end wall

As Produced After testing

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Set

-

_-

up and Processing

_{up and Processing}

• Type of tooling

– Plastic injection molding – Zn or Al die casting

– PIM / MIM

• Operator/Mold Set-up Technician

– Are they familiar with RT material and construction? – Are there special processing

procedures?

– Hand loaded inserts – multiple sets for consistent processing, assembly and disassembly

• Process monitoring –extends life of tool

– Temperature measurement – Pressure measurement

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Conclusions

• Learn & understand each RT process

Adjust dimensions to meet tolerances of Parts and Tools (finish stock) – Quantity of Parts - finite life of tool

• (need to know up front the total part requirement from the tooling)

– Mold Processing and durability (actual versus expected)

– Part Aesthetics – as finished or texture, logos and polished surfaces – Design parts to support the RT process when possible

• simplification may be required, either part or tool

– Future part requirements

• Possible alternate materials or additional quantities (e.g. changes to resolve test failures)

• Research RT supplier capability

– Do they have a Quality Control tracking system in place for parts and tooling? – Tool quality and quantity produced (ask to see sample parts)

– Delivery (issue of PO to delivery of tooling or parts)

– Willingness to communicate problems or notify changes in schedule

• Costs

– Compare costs from several suppliers and RT processes – Quantity and quality of RT produced molded or cast parts

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Conclusions (cont.)

• Plan for failures in design, schedule and tooling

– Consider plan “B” and “what if” scenarios for critical steps

– Do not forget about non-technical aspects of using rapid tooling

• Requires tool core/cavity design work to be completed

before RT fabrication

– Tool design must occur concurrently with part design

• Rapid Tooling from Concept to Production tool

– Most effective as a planned step - not as effective when applied as crisis driven to meet a deadline.

– Part design and CAD file must be complete and error free.

– Part redesign or simplification may be required to shorten schedule. – Secondary operations (example: flash removal, hand loaded inserts) – Rapid tooling parts can/may be different than hard tooled parts and

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Recommendations:

• Select the RT fabrication process that meets/fits your

project objectives.

• Understand the limitations of RT processes.

• Research supplier capabilities.

– Quote several suppliers and/or RT processes.

• Design parts/tools to the manufacturing process (DFM).

• Consult with mold/die designer early and throughout

project

(Southco has a Rapid Tooling Specialist on Tool Design staff) – Keep them abreast of any part design changes.

• Part simplification can save time and money.

• Use standard size mold base pockets and/or insert type

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Questions?

Glenn Anderson

Senior Engineer, Research and Development

Southco Incorporated 210 North Brinton Lake Road

Concordville, PA 19331 Phone: 610.361.6817

FAX: 610.361.6232