Molten Spray Moldmaking
Rapid solidification creates mold and die tooling that is harder than heat treated components, within build times that are faster than machining.
[Editor's note: RSP Tooling, the company mentioned in the article below, no longer has a license agreement related to the Rapid Solidification Process (RSP). Premier Technology (www.ptius.com) now has a license agreement with Idaho National Laboratory related to RSP. A representative of Premier Technology told me the company's aim is to develop and sell machinery for producing large tooling and dies with this technology, but the timeframe for achieving this is unknown. Therefore, the article below is presented as information on an additive manufacturing approach that is likely to be available in the future. —PZ]
Because additive manufacturing processes are not affected by geometric detail, they ought to be ideal for making molds and dies. The complex features of these parts that slow down machining do not have to affect the speed of a process that builds parts layer by layer. However, size is a problem. Equipment for building additive metal parts is typically much more expensive than comparably sized CNC machine tools. Cost, among other factors, prevents additive equipment from scaling up to the size of a large mold or die.
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