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Beyond Stereolithography

Beyond Stereolithography. Presented by: Paul Armstrong. Concepts. Time Compression Cost effective new product introduction Rapid Prototyping Rapid Tooling Functional Plastic and Metal Prototypes Marriage of CAD & RP technology with crafts-based traditional patternmaking skills.

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Beyond Stereolithography

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  1. Beyond Stereolithography Presented by: Paul Armstrong

  2. Concepts • Time Compression • Cost effective new product introduction • Rapid Prototyping • Rapid Tooling • Functional Plastic and Metal Prototypes • Marriage of CAD & RP technology with crafts-based traditional patternmaking skills

  3. “ If everything is under control, you’re probably not going fast enough” Mario Andretti

  4. Why Use Prototypes? • Fit and Function Testing • Design Verification and Refinement • Market Analysis and Funding • Aid for designing production tooling and fixtures

  5. Benefits of RP • Quick production of prototype or model • Model produced from designer’s database • Provides excellent pattern for: • Aluminum castings via sand or plaster-mold • Plastic parts in thermoplastic resins or urethanes

  6. Machined Aluminum Castings • Plaster Mold–RPM • Precision Air-set Sand • Graphite Mold

  7. Benefits of RPM Casting • Aluminum, zinc or magnesium parts in 1-5 weeks • Die Cast Prototyping • Simulates die casting for appearance and physical properties • Soft tooling allows for ease of geometry modification • Relatively low cost- Magnitude of ten rule of thumb

  8. Benefits of RPM • Can be production process for projects that can’t justify hard tooling • Bridge tooling and tooling insurance • Replace lost production tools • Excellent surface finishes • Accommodates complex geometry with undercuts • Thin wall sections with excellent weight to strength ratio • 0.080” wall typical 0.020” wall possible

  9. CastForm – Parts in 1 Week 1 SLS MODEL 1 ALUMINUM CASTING

  10. Precision Sand Casting

  11. Benefits of Precision Sand Casting • Aluminum cast parts in 2-5 weeks • Excellent surface finish and overall casting appearance compared with other sand processes • Superior metallurgical properties

  12. Cast Parts in 2 weeks via RPM or Sand • Day 1: file transfer and interpretation • engineering review and prep part for process • Days 1-2: creation of master pattern • Days 3-5: creation of foundry tooling • Day 6: pour & bake molds • Day 7: pour castings • Days 8-10:secondary operations and qualify castings

  13. Benefits of Graphite Molding • Aluminum, zinc or magnesium parts in 3- 5 weeks • Semi-permanent mold will make hundreds of parts from one tool • Ideal for 100-2000 parts • Short run production • Bridge from prototype process to production • Able to cast spec die-cast alloys: 380, 390 • More accurate test results for tensile, yield, hardness

  14. Tensile Strength- 380 T6

  15. Rapid Injection Molding using Cast Tooling

  16. What is Kirksite? • Zinc-aluminum alloy • 94% Zn, 6% AL • 725° F melting point • Castable, machinable, weldable • Zinc is used to enhance tool life • Kirksite molds have been around for fifty years • SLA/RP technology unlocked real potential

  17. Benefits of Rapid Injection Molding • Prototypes in production thermoplastic resins in a 1-4 weeks • Allows for full functional testing • Relatively low cost tooling made from SLA master • Bridge or production tooling • Molds can run thousands of parts • Cast tooling can be used for many plastic processes

  18. Tooling for Rapid Injection Molding • Prototyping/ Design Verification/Bridge Tool • Cast Kirksite • Sintered Steel • Machined Aluminum • Production • Cast Kirksite • Machined aluminum • Sintered Steel • Machined Steel

  19. Tolerancing Tight tolerance CTF dimensions can be machined into mold or parts Cosmetics Appearance critical areas can be enhanced thru mold finishing Upgrade cooling and ejection Tool life Molds can run thousands of parts depending on material Dupilcate tool easily made from master Materials Glass filled - insert in high wear areas Material temp< 725° F Limitations of Cast Tooling

  20. Cast Tooling vs. Cut AL • Cheaper and quicker • Tooling upgradeable after prototype run • Complex 3D geometry • Compound curves • Angular shapes • Speeds design refinement cycle • CTF quality requirement

  21. RIM- Reaction Injection Molding • Polyurethane molded parts in 2-5 weeks • Excellent flowability and processing allows for molding of: • Complex shapes • Soft and sharp detail • Thick and thin sections • Openings, ribs and louvers • Foamed polyurethanes are natural thermal and acoustic insulators

  22. RIM Benefits • Low internal mold pressures • Low cost tooling allows for ease of geometry modification • Superior cosmetic appearance for visible components • Superb encapsulation capability • Reduction in assembly operations with part consolidation

  23. When to use RIM • Housings, bezels, chassis, bases, doors, speaker enclosures • Visually critical applications • Large plastic parts • Encapsulation requirements • Insulation requirements

  24. Types of RIM tooling • Silicone rubber - handful of parts • Epoxy resin - up to 100 pcs • Spray metal - several hundred pcs • Cast tooling • Machined aluminum • Machined steel

  25. Thank You for Coming Armstrong Mold Corporation6910 Manlius Center RoadEast Syracuse, New York 13057-9597Phone: (315) 437-1517 Email: sales@armstrongmold.com Web: www.armstrongmold.com

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