Slide 1

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 2

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 3

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 4

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 5

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 6

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 7

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 8

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 9

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 10

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 11

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 12

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 13

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 14

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 15

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 16

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 17

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 18

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 19

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 20

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 21

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 22

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 23

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 24

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 25

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 26

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 27

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 28

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 29

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 30

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 31

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 32

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 33

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 34

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 35

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 36

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 37

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 38

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 39

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 40

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 41

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 42

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 43

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 44

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 45

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com


Slide 46

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

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

Mario Andretti

Why Use Prototypes?


Fit and Function Testing
 Design Verification and Refinement
 Market Analysis and Funding
 Aid for designing production tooling and
fixtures

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

Machined Aluminum Castings


Plaster Mold–RPM
 Precision Air-set Sand
 Graphite Mold

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 costMagnitude of ten rule of
thumb

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

CastForm – Parts in 1 Week

1 SLS MODEL

1 ALUMINUM CASTING

Precision Sand Casting

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

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

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

Tensile Strength- 380 T6
50
45
40
35
30
25
20
15
10
5
0

Tensile in KSI

356 T6

356

Graphite

Die Cast

Rapid Injection Molding using
Cast Tooling

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

Benefits of Rapid Injection
Molding


Prototypes in production thermoplastic resins in a 14 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

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

Limitations of Cast Tooling


Tolerancing



– Tight tolerance CTF

– Molds can run

dimensions can be
machined into mold or
parts


thousands of parts
depending on material
– Dupilcate tool easily
made from master

Cosmetics
– Appearance critical

areas can be enhanced
thru mold finishing
– Upgrade cooling and
ejection

Tool life



Materials
– Glass filled - insert in

high wear areas
– Material temp< 725° F

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

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

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

When to use RIM


Housings, bezels, chassis, bases, doors,
speaker enclosures
 Visually critical applications
 Large plastic parts
 Encapsulation requirements
 Insulation requirements

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

Thank You for Coming
Armstrong Mold Corporation
6910 Manlius Center Road
East Syracuse, New York 13057-9597
Phone: (315) 437-1517
Email: [email protected]
Web: www.armstrongmold.com