Mod 5

• Rapid tooling / Rapid prototyping is any method or

technology that enables one to produce a tool or product
quickly
• Produce multiple copies of a prototype with functional
material properties in short lead times.
• Rapid tooling can be classified into soft or hard, and direct or
indirect tooling
• Soft tooling,typically made of silicon rubber, epoxy resins, low
melting point alloys and foundry sands, generally allows for
only single casts or for small batch production runs.
• Hard tooling, on the other hand, usually made from tool
steels, generally allows for longer production runs
• Direct tooling is referred to when the tool or die is created
directly by the RP process.
• As an example in the case of injection molding, the main
cavity and cores, runner, gating and ejection systems, can be
produced directly using the RP process.
• In indirect tooling, on the other hand, only the master
pattern is created using the RP process. A mold, made of
silicon rubber, epoxy resin, low melting point metal, or
ceramic, is then created from the master pattern
 Direct Soft Tooling
• Molding tool is produced directly by the RP systems. Such
tooling can be used for liquid metal sand casting, in which the
mold is destroyed after a single cast.
• As these molding tools can typically only support a single cast
or small batch production run before breaking down, they are
classified as soft tooling
Examples
Selective Laser Sintering of Sand Casting Molds
• Sand casting molds can be produced directly using the
selective laser sintering (SLS) process.
• Individual sand grains are coated with a polymeric binder.
Laser energy is applied to melt this binder which coats the
individual sand grains together, thereby bonding the grains of
sand together in the shape of a mold
Direct AIM
• Uses SLA to produce resin molds that allow the direct
injection of thermoplastic materials.
• AIM stands for ACES Injection Molding. ACES stands for
“Accurate Clear Epoxy Solid,” this method is able to produce
high levels of accuracy
• SL Composite Tooling
• This method builds molds with thin shells of resin with the
required surface geometry which is then backed-up with
aluminum powder-filled epoxy resin to form the rest of the
mold tooling .
• This method is advantageous in that higher mold strengths
can be achieved when compared to those produced by the
Direct AIM method
 Indirect Soft Tooling

• In this rapid tooling method, a master pattern is first produced using RP.
• From the master pattern, a mold tooling can be built out of an array of materials
such as silicon rubber, epoxy resin, low melting point metals, and ceramics
Examples
Arc Spray Metal Tooling
The master pattern produced by any RP process is mounted onto
a base and bolster, which are then layered with a release agent.
A coating of metal particles using the arc spray is then applied to the
master pattern to produce the female form cavity of the desired tool.
Depending on the type of tooling application, a reinforcement backing
is selected and applied to the shell.
Types of backing materials include filled epoxy resins, low-melting point metal alloys
and ceramics
Silicon Rubber Molds
• The master pattern, attached with a system of sprue, runner,
gating and air vents, is suspended in a container.
• Silicon rubber slurry is poured into the container engulfing the
master pattern.
• The silicon rubber slurry is baked at 70°C for three hours and
upon solidification, a parting line is cut with a scalpel.
• The master pattern is removed from the mold thus forming
the tool cavity
• Extremely high resolution of master model details can be
easily copied to the silicon cavity mold and Gross reduction of
backdraft problems are the advantages
 Direct Hard Tooling
Laminated Metal Tooling
• The process applies metal laminated sheets with the
Laminated Object Manufacturing (LOM) method
• sheets can be made of steel
• The CAD 3D data provides the sliced 2D information for
cutting the sheets layer by layer.
• the layers are all assembled after cutting and either bolted or
bonded together.
Direct Metal Laser Sintering (DMLS) Tooling
• The process uses a very high-powered laser to sinter metal
powders directly.
• The powders available for use by this technology are the
bronze-based and steel-based materials
• Upon sintering of the bronze powder, an organic resin, such as
epoxy, is used to infiltrate the part
• For steel powders, the process is capable of producing direct
steel parts of up to 95% density so that further infiltration is
not required.
 Indirect Hard Tooling
3D Keltool
• The process uses a SLA model of the tool
• The model is placed in a container where silicon rubber is poured
around it to make a soft silicon rubber mold
• This is then placed in a box and then silicon rubber is poured around
it to produce a replica copy of the SLA model in silicon rubber
• This silicon rubber is then placed in a box and a proprietary mixture
of metal particles, such as tool steel, and a binder material is poured
around it, cured and separated from the silicon rubber model.
• This is then fired to eliminate the binder and sinter the green metal
particles together. The sintered part which is about 70% steel and
30% void is then infiltrated with copper to give a solid mold, which
can be used in injection molding.
Ecotool
• The process uses a powder material with a binder
system to rapidly produce tools from RP models.
• the binder is friendly to the environment in that it uses
a water-soluble base.
• An RP master pattern is used.
• The metal powder-binder mixture is then poured over
the pattern and parting block and left to cure for an
hour at room temperature.
• The process is repeated to produce the second half of
the mold in the same way.
• The pattern is then removed and the mold baked in a
microwave oven.
 Applications of Additive Manufacturing
Aerospace Industry
1. Design Verification of an Airline Electrical Generator
• Utilization of Rapid Prototyping (RP) technology by Sundstrand Aerospace to
verify the design of an integrated drive generator for a large jetliner.
• Sundstrand utilized Helisys’s Laminated Object Manufacturing (LOM) to create
a design-verification model of the generator, comprised of an external housing
and approximately 1200 internal parts.
• Traditional visualization methods were deemed insufficient due to the
complexity of the design, prompting the adoption of RP technologies.
• Initial CAD designs were converted to STL files and sent to a service bureau for
fabrication, allowing Sundstrand to quickly receive and evaluate physical
models for form, fit, and function.
• The models facilitated the identification and correction of design issues,
leading to improved efficiency in tooling, manufacturing process design, and
assembly sequence planning.
• Despite the approximate cost of $16,500 for RP models, the benefits in time
and cost savings were deemed significant, demonstrating the effectiveness of
RP in design verification and optimization processes.
2. Engine Components for Fanjet Engine
• AlliedSignal Aerospace's application of 3D Systems’ QuickCastTM
technology to expedite the development of a turbofan jet engine for
a business aviation jet.
• The focus was on generating casting patterns for an impeller
compressor shroud, a critical component providing seal for the high-
pressure compressor.
• Three distinct designs were necessary for testing various engine
conditions. Leveraging QuickCastTM, the 3D Technology Center
produced durable, highly accurate patterns directly applicable to
investment castings via stereolithography.
• These patterns not only demonstrated enhanced accuracy and
surface finish but also facilitated the detection and correction of
assembly fixture design errors.
• The adoption of RP techniques resulted in an impressive reduction of
eight to ten weeks in production time and substantial savings of
$50,000 in tooling costs across the three design iterations.
3. Prototyping Air Inlet Housing forGas Turbine Engine
• Sundstrand Power Systems, a prominent manufacturer of auxiliary engines for
military and commercial aircraft, embarked on the development of an air inlet
housing for a new gas turbine engine.
• With dimensions of approximately 250 mm in height and 300 mm in diameter,
featuring thin wall thicknesses as low as 1.5 mm, the complexity of the design
posed challenges for traditional manufacturing methods.
• Sundstrand employed DTM’s Selective Laser Sintering (SLS®) technology to
fabricate evaluation models of the housing and produce patterns for investment
casting, the chosen manufacturing method.
• The decision to utilize SLS® was driven by the presence of intricate overhanging
structures, making support removal arduous through conventional means.
• Iterative design iterations were crafted using CAD software, with solid models
converted to STL format for fabrication of nylon evaluation models. As the design
progressed, successive versions of the part were generated using SLS® for
investment casting tooling.
• Polycarbonate patterns, sealed with wax, were utilized for casting in Iconel 718
steel, subsequently subjected to testing by Sundstrand.
• The adoption of SLS® technology resulted in significant time and cost savings,
with Sundstrand shaving over four months off tooling and prototyping processes,
amounting to savings exceeding US$88,000.
General aerospace applications
• Prototyping: AM enables rapid iteration and testing of aerospace
components, accelerating the design process and reducing time-to-
market for new aircraft.
• Lightweight Structures: AM allows for the creation of lightweight and
optimized aerospace components, reducing fuel consumption and
enhancing aircraft performance.
• Complex Components: AM can produce intricate components with
internal features that are difficult or impossible to manufacture using
traditional methods, such as fuel nozzles, turbine blades, and heat
exchangers.
• Customized Parts: Aerospace companies can use AM to produce
customized parts tailored to specific aircraft models or mission
requirements, improving overall efficiency and performance.
• Repair and Maintenance: Additive manufacturing enables on-demand
production of replacement parts and tooling for aircraft maintenance,
reducing downtime and inventory costs.
 AUTOMOTIVE INDUSTRY
1. Prototyping Complex Gearbox Housing for Design Verification
• Volkswagen has leveraged Helysis’s Laminated Object Manufacturing (LOM)
technology to accelerate the development of a large, intricate gearbox housing
for its Golf and Passat car lines.
• The CAD model for the housing presented challenges in visualization due to its
complexity. Seeking to validate the design and conduct packaging studies,
Volkswagen opted for LOM prototyping, bypassing the limitations and
inaccuracies associated with traditional fabrication methods.
• Utilizing RP technology ensured that the fabrication process precisely mirrored
the CAD model, eliminating human interpretation errors common in traditional
approaches.
• Despite the gearbox housing surpassing the build volume of the LOM machine,
Volkswagen successfully divided the CAD model into manageable sections, which
were later assembled into the final model post-fabrication.
• The LOM prototype served dual purposes: initial design verification and
subsequent development of sand-casting tooling for metal prototypes.
• The RP process dramatically reduced prototype development time from eight
weeks to under two weeks, resulting in significant time and cost savings for
Volkswagen.
2. Prototyping Advanced Driver Control System with Stereolithography
• At General Motors, Rapid Prototyping (RP) has emerged as a crucial tool
in the competitive race to introduce products swiftly to market.
• Delco Electronics, a subsidiary specializing in automotive electronics, was
tasked with the development of the Maestro project, aiming to integrate
advanced audio, hands-free cellular communication, GPS navigation, RDS
information, and climate control into a seamless driver control system.
• Traditional molding methods proved cumbersome due to the sheer
number of buttons. Consequently, models for each button face were
manually machined from stylist concepts.
• Once designs were validated, these models were laser scanned to
generate CAD data for SLA model creation. The SLA models, produced
using 3D Systems’ SLA machine, were accurate, finished, and back-lit,
obviating the need for rubber molds.
• In under four months, Delco Electronics successfully realized the
functional instrument panel, integrating all 108 buttons fabricated
through SLA technology.
3. Creating Cast Metal Engine Block with RP Process
• In response to the costly and time-consuming nature of new engine
development, the Mercedes-Benz Division of Daimler-Benz AG
implemented a program to validate prototype engines using SLA parts for
initial testing.
• Utilizing the QuickCastTM process for rapid metal component
production, their inaugural project focused on designing and prototyping
a four-cylinder engine block for the Mercedes-Benz “A-Class” car.
• The engine block design, originating from Mercedes-Benz's CAD system,
was translated to 3D Systems Technology Center for SLA pattern
fabrication. The one-piece pattern was then utilized for investment
casting, resulting in the production of an aluminum engine block with
integrated water jacket and core passage ways within five weeks.
• The prototype exhibited Grade B radiographic quality in all evaluated
areas. The entire prototyping process, facilitated by RP technology,
spanned only six weeks, representing significant time and cost savings
compared to traditional methods—approximately US$150,000.
• These efficiencies are particularly noteworthy in meeting the demand for
rapid time-to-market requirements.
General automotive applications
• Prototyping: AM enables rapid prototyping of automotive components,
allowing manufacturers to iterate designs quickly and efficiently during the
development phase.
• Customization: AM allows for the production of customized automotive
parts tailored to individual preferences or specific vehicle models,
including interior trim, dashboard components, and exterior accessories.
• Functional Prototypes: AM allows for the creation of functional
prototypes with properties similar to production parts, enabling thorough
testing and validation of automotive systems and components.
• End-Use Parts: Some automotive manufacturers incorporate additively
manufactured parts directly into production vehicles, including
components such as air ducts, intake manifolds, and engine mounts.
• Racing and Motorsports: AM is widely used in racing and motorsports for
the rapid development and production of lightweight, high-performance
components, including aerodynamic parts, suspension components, and
engine components.
 BIOMEDICAL INDUSTRY
1. Inter-Vertebral Spacers
• Spinal vertebral disintegration, a consequence of conditions like osteoporosis or
extreme spinal forces, often necessitates the use of spacers in spinal fixation
procedures.
• Rapid Prototyping (RP) has been explored for producing such spacers due to its
capability to fabricate intricate 3D structures with interconnected pores,
facilitating tissue in-growth.
• Key considerations include biocompatibility and mechanical strength to
withstand spinal loads.
• It involves creating a solid RP master pattern of the spacer, which serves as a
template for a soft mold.
• Stainless steel bearings, coated with a specialized binder system, are cast into
the mold under vacuum, followed by curing and ejection from the mold.
• Subsequent debinding and sintering processes yield the final implant
• The primary advantage lies in using a solid RP pattern to create a porous
structure with customizable pore sizes and mechanical strengths, addressing
crucial requirements for spinal implantation.
2. Customized Tracheobronchial Stents
• The utilization of Rapid Prototyping (RP) techniques in the production
of respiratory stents aimed at maintaining airway patency has been
explored.
• These stents offer customization options to address specific
anatomical considerations and compressive resistance requirements,
tailored by modifying stent wall thickness.
• Actual force measurements necessary for restoring the airway
channel to its original dimensions inform CAD system adjustments to
the stent design.
• Once confirmed, the CAD data is translated into a master pattern via
RP systems.
• Subsequently, the master pattern undergoes silicon molding vacuum
casting to replicate the stent with biocompatible materials, ensuring
strength, spring-back, and anti-migration properties.
• The resulting tracheobronchial stents vary slightly in size for optimal
intra-surgery customization..
3. Scaffolds for Tissue Engineering
• Tissue engineering has emerged as a promising approach for replacing
failing or malfunctioning organs, encompassing various tissues such as
skin, liver, pancreas, heart valve leaflets, ligaments, cartilage, and bone.
• Rapid Prototyping (RP) techniques have garnered interest in
constructing scaffolds aimed at promoting surrounding tissue and cell
in-growth, or as temporary supports for transplanted cells to adhere
and proliferate.
• These scaffolds are designed in three dimensions using Computer-
Aided Design (CAD), considering factors such as porosity and
interconnectivity to facilitate tissue induction.
• The functionality of cells, particularly in bone and cartilage
regeneration, relies on three-dimensional spatial relationships,
underscoring the importance of scaffold geometry.
• RP technologies excel in producing intricate scaffold geometries
essential for successful tissue engineering applications.
4. Knee Implants
• Engineers at DePuy Inc., a leading orthopedic implant
supplier, have integrated Computer-Aided Design (CAD) and
Rapid Prototyping (RP) technologies into their design
workflow.
• This integration enables them to analyze the suitability of
implants for individual patients and make necessary design
modifications accordingly.
• They relies heavily on Stereolithography (SLA) in the
production process for both standard and custom implants.
• Prototypes produced through RP serve as masters for casting
patterns
• . Compared to traditional casting tooling, this approach offers
several advantages, including a reduction in lead time and a
decrease in costs.
 Electronics Industry
• Printed Circuit Boards (PCBs): AM enables the fabrication of complex
PCBs with customized designs, including multilayer boards, flexible
circuits, and embedded components. Additive manufacturing techniques
such as inkjet printing and aerosol jet printing are used to deposit
conductive traces, insulating layers, and solder mask materials layer by
layer.
• Antennas and RF Components: AM technologies are utilized to produce
antennas and radio frequency (RF) components with intricate geometries
and optimized performance characteristics. 3D printing allows for the
fabrication of antennas with specific shapes, sizes, and frequency
response properties, tailored to the requirements of wireless
communication systems.
• Heat Sinks and Thermal Management Solutions: AM is used to fabricate
heat sinks and thermal management solutions for electronic devices,
helping to dissipate heat generated by components and prevent
overheating. Metal AM technologies such as selective laser melting (SLM)
and electron beam melting (EBM) enable the production of complex heat
sink geometries with optimized thermal conductivity and performance.
• Sensors and Sensing Devices: AM technologies are used to fabricate sensors
and sensing devices for various applications, including environmental
monitoring, healthcare, and industrial automation. 3D printing allows for the
production of sensor housings, electrodes, and sensor arrays with customized
geometries and properties, enabling precise measurement and detection of
physical, chemical, and biological parameters.
• Custom Connectors and Interconnects: AM enables the production of custom
connectors and interconnects for electronic devices, allowing for the creation of
bespoke electrical interfaces and cable assemblies. Additive manufacturing
techniques such as stereolithography (SLA) and digital light processing (DLP)
allow for the fabrication of connectors with intricate geometries and precise
tolerances, tailored to the requirements of specific applications.
• Embedded Electronics: AM enables the integration of electronic components
directly into 3D printed parts, allowing for the creation of functional prototypes
and end-use products with embedded sensors, actuators, and circuitry. Additive
manufacturing techniques such as direct ink writing (DIW) and material jetting
enable the deposition of conductive and insulating materials layer by layer to
create embedded electronic systems.