Rapid Prototyping of Tools
Abstract
This report describes a system for rapid tool manufacturing based on the integration of stereolithograph and thermal spraying. With stereolithography apparatus (SLA), plastic prototype models are built directly from a vat of liquid photocurable polymer by selectively solidifying it with a scanning laser beam. Thermal spraying is then used to incrementally deposit metal onto the SLA models. A freestanding metal structure is formed by separating the metal shell from the plastic substrate. By mounting the shell in a frame and backing it up with appropriate materials, a broad range of tooling can be fabricated including injection molds, forming dies, and EDM electrodes. The system integrates SLA and thermal spraying into a CAD/CAM environment which includes design evaluation tools, robotic spray capability, and computer-aided process planning. Information flows efficiently from design through fabrication by incorporating a common geometric modeling system for part and process representations. Our goal is to demonstrate that automating and integrating these processes, within a unified modeling environment, can significantly improve productivity through greater design flexibility, rapid fabrication, and cost-reduction. We have established the system framework and developed several of the system components. This report describes a case-study for the application of this technology to injection mold manufacture. (kr)
Document Details
- Document Type
- Technical Report
- Publication Date
- Oct 01, 1989
- Accession Number
- ADA215956
Entities
People
- E. L. Gursoz
- F. B. Prinz
- Lee E. Weiss
- Paul S. Fussell
- Swami Mahalingham
Organizations
- Carnegie Mellon University