Rapid Tooling

Ed Tackett Director
Saddleback College Advanced Technology Center

Rapid Prototype Uses

Concept Models Prototypes P t t Functional Prototypes Limited Production Manufacturing Rapid Manufacturing Rapid Tooling

Concept Models
A part intended primarily for form or appearance study, but which typically cannot be used to either check fit to other parts, or provide functionality of the final part in an application application.

Rapid Prototypes
Rapid prototyping is the most common name given to a host of related technologies that are used to fabricate physical objects directly from CAD data sources. Th These methods are unique in that they add and b d materials i l th d i i th t th dd d bond t i l in layers to form objects. Such systems are also known by the names additive fabrication, three dimensional printing, solid freeform fabrication (SFF) and layered manufacturing. Today's add e technologies o e ad a ages in many a u ac u g oday s additive ec o og es offer advantages a y applications compared to classical subtractive fabrication methods such as milling or turning: Objects can be formed with any geometric complexity or intricacy without the need for elaborate machine setup or final assembly; Rapid prototyping systems reduce the construction of complex objects to a manageable, straightforward, and relatively fast process. This has resulted in their wide use by engineers as a way to reduce time to market y g y in manufacturing, to better understand and communicate product designs, and to make rapid tooling to manufacture those products. Surgeons, architects, artists and individuals from many other disciplines also routinely use the technology.

Rapid Tooling
The term Rapid Tooling (RT) is typically used to describe a process which either uses a Rapid Prototyping (RP) model as a pattern to create a mold quickly or uses the Rapid Prototyping process directly to fabricate a tool for a limited volume of prototypes RT is prototypes. distinguished from conventional tooling in that: a) Tooling time is much shorter than for a conventional tool. Typically, time to first articles is below one-fifth that of conventional tooling. b) Tooling cost is much less than for a conventional tool. Cost can be below five percent of conventional tooling cost. c) Tool life is considerably less than for a conventional tool. d) Tolerances are wider than for a conventional tool.

Benefits of Rapid Tooling

Time Reduce Waste Conformal C li C f l Cooling Rapid Reconfiguration

The Process
3D Print Process

The Process
Selective Laser Sintering & EOS

Post Processing
3D Print Process

Green Part Low Temperature Sintering Oven Crucible P k C ibl Package High Temperature Infiltration with Bronze Finishing/Polishing

Post Processing
Selective Laser Sintering

Green Part Low Temperature Sintering Oven Crucible P k C ibl Package High Temperature Infiltration with Alloy Finishing/Polishing

Tool Examples

Tool Sample

Cooling Sample

Conformal Cooling Sample

Conformal Cooling Cut Away

Conformal Cooling Explanation

Questions ?
Ed Tackett Director
Saddleback College Advanced Technology Center 28000 Marguerite Parkway Mission Viejo, CA 92692 (949) 582-4831 etackett@saddleback.edu