1 / 36

NDM Rapid Tooling Process for Aluminum and Thermoplastic Parts

NDM Rapid Tooling Process for Aluminum and Thermoplastic Parts. Paul Armstrong John Mathews. NDM Process. Patented program Owned & licensed by B&D Sales Corporation Under development for several years Continuing R&D for improvement Armstrong Mold and B&D Sales working jointly to:

berke
Télécharger la présentation

NDM Rapid Tooling Process for Aluminum and Thermoplastic Parts

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript


  1. NDM Rapid Tooling Process for Aluminum and Thermoplastic Parts Paul Armstrong John Mathews

  2. NDM Process • Patented program • Owned & licensed by B&D Sales Corporation • Under development for several years • Continuing R&D for improvement • Armstrong Mold and B&D Sales working jointly to: • Increase the number of applications • Expand industries that can utilize this procedure

  3. Topics • Benefits of NDM • Design considerations • Process steps • Case study • Where do we go from here??

  4. Benefits of NDM

  5. Core and Cavity • Process yields excellent tool finish • Captures intricate detail

  6. Core in Universal Base • 600,000 shots and still running

  7. Cavity • Ideal for geometrically complex shapes

  8. Benefits • Versatility • Die casting • Thermoplastic injection molding • MIM (metal injection molding) • Fast turnaround, low cost • 2 weeks from CAD file to part • Mold hardness • Extended tool life • Quick cavity duplication • Ideal for multi-cavity molds

  9. Design Considerations • Cavity/Core insert size • 1” x 1” x 1” to 4” x 6” x 2” • Complex angular/curvaceous shapes • Part materials • Aluminum • Most thermoplastics • Most MIM materials • Draft angles • Industry standards with radii and fillets

  10. Design Considerations • Wall thickness • Die casting industry standards • Injection molding industry standards • Tool life • Prototype quantities to 100,000+

  11. Process Comparison :Injection Molded Plastics

  12. Process Comparison:Metal Die Casting

  13. NDM Process Steps

  14. Step 1 – Engineering Review • Prep of e-model • Add shrink • Add draft

  15. Step 2 – Build Pattern • Create master model • SLA • CAM

  16. Step 3 – Rubber Mold • Create pattern • Negative impression from master • Using RTV

  17. Step 4 – Prepare Mold • Treat rubber mold with mold release

  18. Step 5- Fill Mold • RTV molds filled • Stainless steel powder • Proprietary binder

  19. Step 6 - Baking • Green work piece is baked • Removes liquid binder

  20. Step 7 – Furnace Cycle • Work piece is heated in vacuum furnace • Burns off binder

  21. Step 8 - Infiltration • Infiltrate with bronze to full density

  22. Step 9 – Prep Inserts • Finish inserts and prep for mold base • Rig mold • Load into die cast machine

  23. Step 10- Run Parts • Cavity mounted in mold base

  24. Step 10- Run Parts • Core with ejector pins out • Note gates and runners

  25. Step 11- Finish part • Raw casting with runner still attached

  26. Step 11- Finish part • Casting – both sides • Runner now removed • Part ready for de-flash

  27. Step 12- Finished Part • Finished part • Machined in tight tolerance features • Satin Nickel Chrome Plating • < .001” thick

  28. Case Study - Camera Housing • Initial prototyping • SLA • CNC hogouts • DFM analysis • Improved casting design • RPM casting • Initial 20 prototypes • Aluminum (functional)

  29. Case Study - Camera Housing • Product development refinement cycle • 3 revisions • Samples via RPM • Bridge to production • RPM for 4000 parts • RPM cost • Tooling: $5,000 • Casting: $19.85 each

  30. Case Study- Camera Housing • CAD to usable die-cast parts • NDM in only 4 weeks • NDM cost • Die: $12,000 • Casting: $3.30 each • Tool payback/breakeven • 725 pieces • Ramp up • RPM: 100 per week per tool set • NDM: 1,000’s per week

  31. Where do we go from here? • Larger parts • Faster turnaround • Compete with off shore and others for production applications

  32. Where do we go from here • Apply to other processes • MIM-Metal Injection Molds • Thermoplastic Injection Molds • Investment wax tools

  33. Injection Molded Plastic • Plastic- Noryl 873

  34. MIM- Metal Injection Molding • Nickel/ Steel Alloy

  35. Questions www.armstrongmold.com Paul Armstrong - sales@armstrongmold.com John Mathews - jmathews@armstrongmold.com

  36. To Obtain Information Regarding The Licensing of The NDM Process Contact:B&D Sales Corporation19 Fifth AvenueCranston, RI 02910sales@bdsales.com401-781-4810Fax: 401-781-5580

More Related