making the leap to rapid tool making.

Rapid prototyping of tools and molds provides an economical alternative to traditional processing.Rapid prototyping of tools and molds provides an economical alternative to traditional processing.Quick knife making (RTM)Rapid prototyping technology (RP)Technology, and its application in tool and mold manufacturing, is becoming an increasingly attractive alternative to traditional processing.The shift from traditional processing methods to RTM is not so much a step as a leap.aided design (CAD)from drafting.RP, also known as Free shape manufacturing, uses an additional process to create physical geometry directly from a CAD file, replacing the method of removing the material.There are usually several steps required for RTM to create a tool or mold.

In the indirect method of RTM, the RP creates a pattern for forming the tool-For example, after investment casting is stereo printing.Another type of RTM direct production tool-For example, the adhesive is printed on the metal powder and then sintering and penetration.When implemented in a parallel engineering environment, RTM has the potential to significantly increase the speed and cost of product development.Using computer-Assisted design, electronic data transfer, process simulation, and RTM technologies can reduce mold costs and development times by 75% or more.RTM is particularly useful when tool geometry makes traditional machining difficult due to part complexity or specific geometric features such as undercutting.

RTM achieves high by reducing tool costsBatch processes, such as injection molding, are competitive at lower production volumes.The benefits are the biggest for the mass production and value reduction sectors --to-Consumer electronics, auto parts, toys and other markets.Toy manufacturers prefer to develop and distribute a large number of products early in the fall, allowing the market to decide which products to produce in bulk and rapidly increase the production of those products that are successful on store shelves.This approach requires the ability to quickly produce tools and molds for award-winning toysIt is an ideal application of RTM technology.The main RP technologies include stereo forming, selective laser sintering, 3-D.

Printing, modeling of molten deposition, manufacturing of laminated objects and soldier processes.In stereo printing developed by 3D SystemsCuring photosensitive resin with UV laser.Commercial selective laser sintering of DTMAustin, Texas.Involving laser-Induced fusion of polymer or polymercoated powder.In 3-D printing developed by MIT, adhesive is inkSpray on the powder.

Modeling of molten deposition developed by StratasysEden Prairie in Minnesota, Involving hot plastic extrusion.Manufacture of laminated objects developed by HelisysIn Torrance, California.The paper is cut by laser.Soldier, developed by stereo AmericanIn Warren, Michigan.UV curing involving a layer of resin at a time (Other techniques deal with one point in one layer at a time).

Alternative RP technologies such as inkJet Printing of wax or resin (Not a binder), Is being developed at the beginning-Ups such as Sanders and solligan, E.And other Fortune 500 companies.I.DuPont De in Moore the companyand IBM Corp.And universities like MIT, the University of Texas at Austin and Carnegie Mellon.

Several plastic manufacturers including 3m Company, Ciba-Geigy Ltd.And United signal Corporation, Develop and commercialize professional materials for RP.These technologies are being used by many manufacturing companies and service bureaus to manufacture prototype parts for design review and testing in product development and as a step towards production tools.While the US is leading the RP industry, there are significant developments in Europe, Israel and Japan.For example, Teijin Seiki in Osaka, Japan produced UV curing resin for stereo molding, producing parts with great improvement in structural performance, which for mold or low for prototype manufacturing processMass production.

RP annual revenue of about $0.billion, worldwide growth at more than 30% per year.RTM is still in the growth stage.It has the potential to change the basis of competition, but it is not fully embodied in the tool yet --making process.At present, many technologies such as QuickCast, 3D printing and RapidTool have been successfully developed.

Rapid prototyping is an indirect process in which stereoscopic molding creates a mold geometry or pattern in the cellular structure of the polymer material.The pattern was then cast into a metal mold.Many traditional processes and materials, such as epoxy, rubber, plaster and ceramics, can form molds from patterns.D printing and quick tools are a direct process.D printing of mold geometry in metal powder with polymer adhesive, then sintering and penetration to form metal mold.

RapidTool involves selective laser sintering of polymersThen penetrate the coated metal powder forming the metal mold.Tools that RTM is being used to create high prototypesVolume process and lowMass production applications.Ford Motor Co.For example, use RTM to produce metal molds for plastic parts on its browser line.Bose Corp.

Use RTM to create parts for a successful bid package for the car app.Pitney Bowles Inc.Use this technology to make chemical bonded ceramic molds for the base of the new stamping machine.Using RTM, DePuy USA produces tools for hip handle implants.Other methods for RTM include steam deposition and spraying processes for depositing metal layers onto physical geometry, which may have been created by one of the RP technologies or other processes.

The layer forms the surface of the mold, supported by cast epoxy or metal.RTM is not a worry without growth.The technology has limitations in accuracy, speed and capability, limiting its current prototype and lowvolume tooling.These restrictions are being addressed in development efforts and are expected to be eased in the near future.As the technology becomes more user-friendly and robust, there will be no need for such a high level of expertise in RTM.

Traditional toolsIn order to cope with the threat of RTM, manufacturing technology may be improved, just like the improvement of automotive steel plates, as the car body is increasingly replaced by reinforced plastic.General purpose plastic for work, Pittsfield, quality.Other companies said that by improving process management and concurrency (Not in order)Tool development.Computer numerical control and engineering data management are improving the ability of traditional metal removal processes for manufacturing tools.Industrial response to manufacturer of RTM original equipment (OEMs)Ford, Texas Instruments, United Technologies and DePuy are pushing the technology to parts suppliers and tool manufacturers.

Leading manufacturers of tools and molds such as Santin Engineering Inc.Laserform Inc.Technology Products CompanyRTM technology is implemented.These early adopters are able to provide early process validation and faster turnaround for their customers.Other parts suppliers and tool manufacturers will find that they need to develop RTM technology to meet the needs of more OEM support for product and process development.

Tool-and die-Enterprises should develop a consistent business and technology plan based on changing customer needs, industry structure and existing technologies.They may choose to support the customer for "one-stop shopping.This goal requires capital and starts investing in RTM and several other product development features.This investment in product development and rapid tool manufacturing should be closely coordinated with strategic customers to ensure consistent expectations of product development roles and responsibility, as well as compatibility of hardware and software.Alternatively, tool and mold manufacturers can choose a narrower business goal, choose to be independent of specific customers, and make corresponding different and more modest technology investments.

This strategy may include working with other organizations to meet the needs of customers.Some RTM methods, such as QuickCast, use several different technologies, each of which requires different capital equipment and expertise.In this case, RTM may be best implemented by a company team.Ford, for example, worked with Laserform to produce stereo printing for Howmet Corp.Used for investment casting, ATC Nymold for tool manufacturing for production of browser wiper module cover mold.

Depending on the resources and expected usage, the selected process can be implemented in an internal or external service company.Peter Hilton is the president of technology strategy consulting, based in Concord, Mass.