Additive Manufacturing

Rapid Tooling Techniques

 Rapid Tooling
Prototyping vs Tooling

• Introduction
• Silicon Rubber Molding
• Epoxy Tooling
• Spray Metal Tooling
• Cast Kirksite Tooling
• 3D Keltool
Silicone Rubber Molding
(Vacuum Casting)
 Silicone Rubber Molding (Vacuum Casting)

• This process is also known as vacuum casting (as applied to non-metals!).

• Silicon rubber molds can be used to make polyurethane parts such as the bodies of
telephone and other gadgets. These latest polyurethane materials are competing with
ABS, Nylon and Polypropylene (PP) which were popular in these applications. Table in
the next slide gives a comparison of these materials.

• Room Temperature Vulcanizing (RTV) rubber is used to make the mold.

• Typical yield is 15 to 50 parts depending on the geometric complexity. Therefore, this is

ideal for “soft tooling” and to some extent for “bridge tooling”.

• AM has linear cost. Therefore, it will be economical to make the first part with AM and
replicate it using vacuum casting.
Properties of Polyurethane

• SG95, SG200, SG2170 are the latest polyurethanes. ABS, Nylon 6 and Polypropylene (PP)
are given for comparison.
Steps

• A master pattern is prepared. Formerly this used to be prepared using hand carving,
manual or CNC machining. Now these master patterns can be made using AM. Almost any
AM model can be used. SLA, SGC, SLS, LOM and FDM models have been successfully
tried. The master pattern should be nicely polished and cleaned before use. This is because
the process can faithfully reproduce even finger prints on a glass. SLA is the most
preferred.

• A sprue is mounted on the master and glued. This assembly is wiped clean with a soft cloth
moistened with isopropyl alcohol. Hand gloves are to be used during handling these.

• A wooden or metal box is used for preparing the mold. The pattern-sprue assembly is
placed inside on top of thin supports. If feasible, it can be suspended by a thread from the
sprue.

• The liquid silicone RTV resin is mixed with its hardener under vacuum to eliminate air
bubbles.
Steps

• It is then poured into the box over the pattern while still under vacuum.
• The assembly is then placed in a low temperature curing oven maintained at about
50°C for about 6-12 hours. Thus curing takes place under vacuum at a slightly elevated
temperature.
• This process is exothermic. Thus, some parts of the mold will have more temperature
than the oven. Therefore, after the curing period, the oven should be slowly cooled to
room temperature.
• The solidified RTV mold is extracted from the mold box. This is split into two halves
by cutting along an appropriate wavy parting surface using a sharp knife or scalpel.
• The parting surface must be wavy at the outside so as the locate the halves on each
other. However, the inside of the parting surface shall be smooth and ensure extraction
of the part. Cutting this parting surface is a skilled job mastered over a period.
Steps: Part Preparation

Master model can be created using any one of the

current modeling techniques.

Establish the model’s eventual parting line using

clear adhesive tape.
Steps: Mold Preparation

Colour the tape edge with a marker pen to assist in removing master
model from mold. Alternately, a colored tape could have been used.

A casting frame is constructed. Casting gates are attached to the model.

Model is suspended in the casting frame and venting rods are attached

De-gassed Silicone rubber is then poured into the casting frame

Steps: Mold Preparation….

Further degassing in the Vacuum Casting Chamber the tool is moved to

Oven for further curing

When fully cured , the silicone rubber is then cut following the
visible parting line marked on the tape edge

The master model is removed from the mold.

The tool is taped together and prepared for casting. One can also use
stapling.
Steps: Mold Preparation….

Part A & B are precisely measured by weight as per part weight. Color
pigments may be added as required.

Part A & B containers are kept in the chamber, mixed and stirred. It may
also be done manually outside.

A + B is mixed and poured down

through the flexible hose into the mold
Steps: Preparing Multiple Prototypes

After curing in the oven the cast resin prototype is

removed from the tool

Casting gates and the runners trimmed off….

Wavy Parting Surface in Silicon Rubber Mold
Silicon Rubber Molding without parting
Silicon Rubber Molding with parting
Advantages

• Fast and economical.

• As it is flexible, slight reentrant or undercut features can be produced. There is also no

need for draft. So it produces accurate parts.

• Reproduction accuracy is extremely high. Even transparent parts such as lamp lenses
can be made. Even fine scratches on the master get reproduced faithfully. Therefore,
the master should be polished and cleaned before used for mold making.

• Suitable for many resins.

• Used in jewelry industry for producing the wax patterns.

Limitations

• As the mold is soft and will deform under pressure, it cannot be used for injection
molding. Only vacuum casting is possible which is labor intensive. Clamping and
injection pressures have to be low.

• Not suitable for metals.

• Long cycle times of 4-6 hours of part curing for a size of about 8 in3. This is due to poor
heat conductivity of the mold.

• Relative strength of mold limits its life. Therefore, high piece price

• Few suppliers (Huntsman, GE Silicon etc.)

Silicon Rubber Mold Application - Golf Club
Silicon Rubber Mold Application - Bracket
Vacuum Casting Silicon Mold Made from Kira’s Paper Master

Silicon Mold

Master
Urethane Sample
Applicable materials:

• Rubber
• ABS + Glass filled ABS
• Clear transparent
Epoxy Tooling
Features

• Silicon rubber mold is for making part that may have little undercuts. Epoxy tooling is

meant for parts that can allow draft. This is because these molds are more rigid than the

rubber molds. Epoxy is stronger and cheaper than rubber. Therefore, it can be used on an

injection molding machine or on a press.

• Two-part, neat or Aluminum-filled epoxy is cast onto a pattern. When Aluminum powder

is mixed with epoxy, it is called Composite Aluminum Filled Epoxy (CAFE) tooling.

This enables the process used for making stronger parts or more shots. AIMS is an epoxy

process patented by 3D Systems.

• Typical yield is 100 to 200 injection molded parts.

Comparison of Silicon Rubber Molds and Epoxy Molds
Steps
1. Mold box preparation:

• A master pattern is prepared. It is polished to remove stair steps and cleaned.

• A thin film of commercially available mold release agent is applied on the pattern.
• Prepare a mold box of suitable size keeping in mind the dimensions of the injection
molding machine. Note that the outer surfaces of the mold halves will be used for
location and hence the interior surfaces of the box shall be accurate.
• The pattern is then placed in the mold box at the desired orientation. By this time, a
parting surface should have been identified. If it is planar, a simple wooden parting
board can be used. However, if it is more complex, then a machined parting board is to
be used. As the entire weight of the liquid epoxy is supported by the parting board, it
must be strong enough.
• Conformal cooling ducts can be obtained by placing suitably bent copper tubes that run
close to the contours of the pattern with adequate clearance.
• Location pins can be placed if required.
Steps...

2. Epoxy preparation:

• A suitable two-part epoxy (resin and hardener) is mixed in the specified proportion and
quantity.

• Required quantity of finely ground Aluminum powder is mixed with this.

• This is kept in a vacuum chamber to degas the bubbles.

Note: The epoxy for each side should be prepared separately as there is considerable time
gap between the two pours. The other alternative is to make the master pattern in two
halves as is done in sand molding – along with the parting surface in one of them.
However, this is generally not practiced as (i) RP patterns are expensive and (ii) mold
shift will affect accuracy.
Steps...
3. Pouring:

• After keeping the mold box prepared earlier, this composite epoxy liquid is poured

over the pattern under vacuum. If possible, vibration can be provided during pouring.

In order to reduce the cost, the pieces of old molds can be added.

• It is allowed to cure for a few (6 to 12) hours.

• Then the mold is inverted and the parting board is gently removed. The release agent

is applied on the exposed surface of the epoxy and additional coat of release agent can

be given on the pattern also.

• Pour the freshly prepared composite epoxy on this side as before.

Steps...
4. Finishing:

• After curing, the two parts are separated and the pattern is removed.

• Ejection holes are drilled and ejection pins/ plates are installed. For small batch,

these may not be required as one can remove the part manually.

• Finally the mold is mounted on standard tool base. Other assemblies such as

connections to cooling channels are made.

Advantages and Limitations

Advantages:

• Fast and economical

• Suitable for many resins
• Can be used for injection molding

Limitations:

• Relative strength of tool

• Low clamping and injection pressures
• Long cycle times
• High piece price
• Few suppliers
Epoxy Tooling of an Injection Mold
Epoxy Tooling of an Injection Mold
Spray Metal Tooling
Features
• Metal spraying or plasma spraying technology, sometimes known as Hard facing exists

for a long time. This spray can be used in two ways:

(i) making the surface conductive. This is called metallizing. The metallized prototype can be used as a EDM

electrode or polished and used in an application directly.

(ii) making it stronger by building a thicker layer. This can be further backed up and used as a mold.

• Metal is melted using an electric arc, atomized and sprayed directly onto a pattern.

Note that the metal is almost at room temperature when it falls on the pattern. The

resulting shell is backed with a rigid material.

• The most commonly used spray metals are alloys of zinc (eg. Kirksite), nickel, copper

and aluminum.

• Typical yield is 100 to 1,000 injection molded parts.

• As the mold cavity is metal, it is possible to even mold metals using this process.
Principle

• The metal to be sprayed is available in the form of wire similar to MIG welding. Two

wires are fed from two spools. These wires are two ends of a AC power supply.

• The wires are continuously fed to maintain the required deposition rate. Initially a

short circuit occurs causing the ends to melt. Subsequently a constant gap is

maintained in which an arc is sustained. When compressed air is passed through the

arc, it atomizes the molten plasma and sends it as a spray. The air also is responsible

for the rapid cooling of the jet which reaches the pattern at a sufficiently low

temperature as not to damage the pattern.

 Coating Using Cold Metal Spray

• This metal component on the right was produced by spray depositing tin onto the
plastic pattern on the left. Virtually any common tooling alloys, as well as exotic
materials can be used for the spray.

[http://www.memagazine.org/backissues/june00/features/tools/tools.html]
Steps

• The pattern and mold preparation is very similar to epoxy tooling.

• The master pattern is prepared as usual. A thin film of commercially available mold
release agent is applied on the pattern.
• The pattern is kept inside a mold box. A parting board is placed.
• When the spray stabilized, it is sprayed so as to create a consistent shell of about 1 to
2 mm thick on the pattern and parting board. The temp of the spray is from 50°C to
100°C depending on the application.
• Subsequently it is backed up with mixed two-part resin and solid resin particles.
• After the resin backing is cured, it is reversed and the parting board is removed. The
releasing agent is sprayed again.
• The metal spray and backing up are repeated for the second half also.
• Finally, the two halves can be prepared for whatever application it is meant for.
These halves can be used for thermoforming, injection molding, blow molding, sheet
metal forming, vacuum casting etc.
Steps
Preparing the Mold Cool Spraying the Model

Backing up the Sprayed Shell Finished Mold

with High Temp Resin
 Tool Steel Inserts Made Using Metal Spray

These P20 tool steel inserts are used for plastic injection molding. The cavity on the left has
been prepared for use in a mold base, enabling completion of tools in a matter of days.

[http://www.memagazine.org/backissues/june00/features/tools/tools.html]
Advantages and Limitations

Advantages:
• Fast and economical
• Suitable for many resins and metals
• Suitable for large, highly contoured parts
• Size is not a limitation.

Limitations:
• Relative strength of tool
• Low clamping and injection pressures
• Narrow, deep features are difficult to replicate
• High piece price
• Few suppliers
Cast Kirksite Tooling
Features

• Kirksite is a Zinc alloy.

• It can be used for making the tools for

–deep-drawing, forming, punching and blanking of light alloy brass and steel sheets

–plastic injection

–thermoforming

–blowing.

• This tool is made using gravity die casting.

• Typical tool life is 500 to 1000 injection molded parts.

• Kirksite offers optimum economy for parts (sheet or plastic) production in small and

medium series and for tooling setting.

Features…

• The fluidity of Kirksite being excellent, dies can reproduce the thinnest details and

deformation during cooling is minimum, enabling a considerable reduction or even

elimination of post-foundry operations (machining, fitting).

• To improve the mechanical functions such as handling of these tools, lugs, reaction

plates, locating pins, guide-rails etc. may be integrated as steel inserts.

• Kirksite has good friction properties, satisfactory wear resistance, ease of polishing,

suitability for tool storage in atmospheric conditions and recyclability (being Zinc

alloy).

• Kirksite tooling generally is less accurate and more expensive than aluminum-filled

epoxy, or spray metal tooling. It has more transfer steps than either of those methods.

Kirksite tools have about the same life as spray metal or aluminum-filled epoxy tools.
Advantages and Limitations

Advantages:
• Mechanical properties
• Molding temperatures and pressures
• Suitable for nearly all resins
• Recyclability of the material

Limitations:
• Accuracy
• Fine features
• Possible distortion of tool during casting process
• Limited supplier selection
A Sheet Metal Forming Die
3D KelTool
Features

• This is an indirect metallic RT from 3D Systems. This was originally developed by 3M

(manufacturer of magnetic tapes, adhesive sprays etc.). Historically 3D and 3M are
together. The ground work for SLA was also done originally by 3M.

• This is a secondary process suitable for making all kinds of tools for making parts of all
materials. This can be used for bridge tooling as well as production tooling in “prototype
timeframe”.

• The hardness of the inserts is 30-34 RC and 46-50 RC after heat-treating. This hardness is
comparable to the conventional made tools.

• This is a combination of silicon rubber molding and the post-processing used in SLS.
Hence, it involves a two-level molding.

• Typical tool life is dependent on the selected material, but capable of producing in the
100,000's.
Steps • The CAD models of the inserts for core and cavity are made with suitable
allowances. These patterns are then made using SLA. In principle, any RP process
can produce this pair but SLA is used for two reasons:
–KelTool is from 3D Systems and hence they will prefer SLA.
–SLA parts are the most accurate.
• Once these core and cavity patterns have been polished to the desired surface
finish, silicone rubber is cast against them to create molds. The obtained molds will
be negative of the desired molds.
• Into this silicon negative molds, a mixture of metal powder and binder is poured,
packed and cured. The metal mixture consists of finely powdered A6 tool steel and
even finer particles of tungsten carbide.
• At this point, the cast core and cavity inserts exist in a green state. These green
inserts are fired in a hydrogen-reduction furnace to burn away the binder, sinter the
metal particles and infiltrate copper into the inserts. This produces solid metal
inserts that are approximately 70 percent steel and 30 percent copper with physical
properties similar to that of P20 tool steel. The inserts are finish-machined, drilled
for ejector pins and fitted into mold bases.
Steps …

Need for a two-level molding unlike epoxy tooling:

-Excellent reproduction accuracy of silicon mold.
-Flexibility of rubber enables easy removal of the tool in green state.
SLA Pattern, RTV Rubber Mold and Steel Inserts