Rapid Tooling and Metal Parts by Additive Fabrication

Rapid Tooling & Metal Parts
by Additive Fabrication
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Commercially-available DIRECT Tooling and Rapid Manufacturing Processes

Process Technology Suppliers Inj Mold Lead Time Inj Mold Applicable Quantities Inj Mold Relative Cost Inj Moldable Materials Mold Parameters Tolerance (in/in) or as designated Hardness Surface Finish Part Size Limitations Process Materials Strengths Weaknesses

CNC Aluminum Tooling Many 4 to 16 wks 50 to 100,000's $4K to $25K thermoplastics +/- 0.001 in/in n/a Excellent accuracy and finishes;
long tool life Slow, expensive for complex parts

Direct Metal Laser Sintering (DMLS)
(Bronze alloy) EOS GmbH and
service bureaus 1 to 4 wks 100's to 1000 thermoplastics 0.0013 350 u in from machine; 120 u in after shot peening 10 x 10 x 7 in bronze alloy Conformal cooling;
no burnout cycle;
90%+ density
Limited tool life,
lower pressures,
conformal cooling channels have limitations due to powder removal

Direct Metal Laser Sintering (DMLS)
(Steel) EOS GmbH and
service bureaus 1 to 2 wks 100's die cast parts; 100,000's most plastics thermoplastics, metals +/- 0.001 to 0.002 in/in Brinell 60 to 80 Rz = 20 microns (shot peened) 10 x 10 x 8.5 in steel, stainless steel, cobalt chrome, titanium Conformal cooling;
no burnout;
accuracy
surface finish
may require finish machining;
conformal cooling channels have limitations due to powder removal

Selective Laser Sintering (SLS) 3D Systems and
service bureaus 3 to 4 dys for inserts w/ no finish'g, 5 to10 dys if finish req; 2 to 5 wks might be typical range 100's of Zn, Al, Mg die cast parts, 100,000's most plastics $4K to $10K thermoplastics, metals typical inj molding press and temp 0.003 in layers; +/- 0.003 in/in, 0.005 details ; 0.005 to 0.010 in for most dimensions Rb 87 5 microns or D-3; 1 -3 micro in or A-2 to A-3 after polishing 22 x 22 x 30 in (D) steel, stainless steel Conformal cooling;
die casting;
can take typ inj mold press and temp;
Largely unattended operation;
98% density
Requires burnout and infiltration cycle;
may require finish machining;
conformal cooling channels have limitations due to powder removal

Selective Laser Melting (SLM) MCP-HEK Tooling GmbH and
service bureaus 1 wk Inj Molding: 100,000 to 250,000; stampings: 3000+; die casting: 3 to 5,000 thermoplastics, metals Same as typ inj molds +/- 0.001 See strengths < 10 microns 10 x 10 x 10 (appx.) tool steels, stainless steels, pure titanium and cobalt alloys Can use any powdered material;
props. same as intrinsic material;
fully dense parts;
conformal cooling possible but powder must be removed from channels
Limitations on wall thickness and overhangs

Electron Beam Melting (EBM) Arcam AB and
service bureaus 2 to 4 wks Inj molding: > 1,000,000; die casting: > 100,000 thermoplastics, metals Same as typ inj molds +/- 0.012 H13 tool steel; can be hardened 800 to 1600 u in; requires finish machining 8 x 8 x 8 H13 tool steel, low alloy steel, titanium alloy (Ti-6Al-4V), pure titanium Fully dense parts;
energy eff. process;
potential for many materials;
conformal cooling but powder must be removed from channels
Limited part size;
slow cool-down;
requires finishing

ProMetal^TM ProMetal Div. of ExOne Co. 1 wk 100,000's thermoplastics up to 30K psi + - 0.005 + 0.002 in/in Rc = 30 to 35 requires finish machining 20 x 40 x 10 in steel & bronze alloy 60% steel / 40% bronze helps heat cond;
conformal cooling;
structural mass red technology for improved therm isolation;
Inconel Aluminum and Gold possib.;
99%+ density
lots of finishing required

Directed Metal Deposition System DMDS^TM
[based on Sandia's LENS �] Optomec and
service bureaus 2 to 4 weeks 10 to millions thermoplastics, metals Same as typ inj molds X-Y: 0.002 in acc and resol; Z: 0.020 in acc and resol Rc 45 to 60 requires finish machining 18 x 18 x 42 H13 tool steel, 304 and 316 stainless steels, nickel-based alloys such as Inconels, and cobalt-chrome and Ti-6Al-4V alloys Fully dense H-13 tool steel;
mold repair possible:
Multiple materials;
conformal cooling
Geometric limitations on overhangs;
requires finish machining

Direct Metal Deposition DMD^TM POM-Group 2 to 5 weeks (10 x 10 in tool) to 12 to 16 wks for larger tools 10 to millions 20% more than traditional CNC thermoplastics, metals Same as typ inj molds +/- 0.005 Rc = 50 requires finish machining 24 x 24 in H13 tool steel, 304 and 316 stainless steels, nickel-based alloys such as Inconels, and cobalt-chrome and Ti-6Al-4V alloys conformal cooling;
repair or modify std molds;
polishable
Geometric limitations on overhangs;
requires finish machining

Alternative Processes...

Space Puzzle Molding^TM Protoform GmbH 2 to 4 wks up to 1000 $2K to $10K; up to 50% of conventional mold cost thermoplastics normal high volume molding parameters for each plastic; up to or 700 metric ton clamping force; 5 oz. shot max. same as standard injection molding: 0.001 to 0.002 in with hard AL tools depends on mat'l of puzzle segments depends on mat'l of puzzle segments 8.5 x 15 x 30.5 in up to 700 metric ton clamping force mostly uses aluminum, but steel also possible Can use high volume mold parameters;
aluminum mold segments can be made by high speed cutting, yielding 50% saving time on complex parts
Manual loading and unloading and reassembly of mold for each shot;
limited to about 1000 parts;
cost per part higher than conventional process

STAT^TM
[CNC machined composite] Catalyst PDG small parts: 6 days small parts: 6 days; medium parts: 10 days; large parts: 15 days up to 1,500 or more small parts: $3 to $6K; medium parts: $11 to $18K; large parts: $19 to $28K all thermoplastics except some ultems, phenolics and silicones 50 to 500 ton press +/- 0.005 Rc 44 after tempering light texture to a mirror finish, but subject to wear 12 X 21 X 23 in composite tight tolerances,
lead time,
choice of resins
price
tool life,
phenolic and silicone resins,
single supplier

Ultrasonic Consolidation (UC) Solidica 1 wk or less more than 5,000 n/a n/a n/a +/- 0.002 to 0.005 15 u in, equiv to a machined surface 24 X 36 X 10 aluminum, copper and other metals, and combinations and composites in development Conformal cooling;
low-cost mat'ls & multiple suppliers,
fully-dense,
potential range of mat'ls,
embedded components,
good surface finish
shorter tool life than other additive methods

Fast4M Fast4M typically 2X faster than CNC more than 100,000 n/a n/a n/a equal to CNC Rc 42 achieved equal to CNC tools as large as 7 X 4 feet, and weighing more than 15,000 lbs have been built any steel or aluminum alloy; other materials also possible Conformal cooling;
low-cost mat'ls & multiple suppliers,
fully-dense,
good surface finish,
large sizes,
long tool life
possibly not as fast overall as some other additive technologies

Process Technology Suppliers Inj Mold Lead Time Inj Mold Applicable Quantities Inj Mold Relative Cost Inj Moldable Materials Mold Parameters Tolerance (in/in) or as designated Hardness Surface Finish Part Size Limitations Process Materials Strengths Weaknesses

Commercially-available DIRECT Tooling and Rapid Manufacturing Processes

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