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Author Kevin Brooker, Stewart Davis, Bell Helicopter and 3D Systems; Tel 949-388-4227
Source Rapid Prototyping & Manufacturing 2000
Abstract A thermal form tool (1500mm, by 600mm, by 600mm) was created using the 3D Systems SLA 5000 and Ciba Giga SL 5530HT Resin. The tool was created to form polycarbonate glare shields for Bell Helicopter's 609 Commercial Tilt Rotor Project. As of August 18, 1999, twenty (20) pieces of varying thickness have been produced. (The forming temperature of the polycarbonate sheets being approximately 183 - 216 deg C.) The intended purpose of the tool was for a short production of nine parts, but the tool may be utilized for production.
Because of the size of the tool, it was created in four separate sections. The sections were thermal cured and then bonded together and mounted to the tool holder. Several challenges were faced during the project, including: Current recommendations related to thermal curing; Possible warping; Cracking; Drilling recommendations; Tool assembly; Tool size and handling; CAD modeling of the tool; Part release.
These challenges were successfully met, along with the unexpected challenge of having to invert the tool for the thermal forming machine being used. The successful use of this tool has encouraged Bell to use SL 5530HT for other smaller thermal forming and composite lay up applications. XX