Growing demand for cost-effective and faster tooling solutions has given rise to the development of several new rapid tooling methods around the world. Different organizations and manufacturers are developing and commercializing different custom rapid tooling methods due to their expanding potential in the market. Every method has its strengths and limitations, which makes it ideal for different niche applications.
Rapid tooling refers to a process that’s a combination of rapid prototyping and conventional tooling methods. These methods combine to create a mould in a much shorter period and to produce pieces of a functioning model via the CAD data that was pre-fed, much faster and more cost-effective compared to traditional tooling techniques.
One of the primary benefits of rapid tooling is that it considerably reduces tooling time and cost compared to traditional tooling processes. What are some of the most significant rapid tooling services techniques? Let’s find out.
1. Room Temperature Vulcanizing Silicone Rubber moulds
Room Temperature vulcanizing silicone rubber moulds are among the most widely used tooling applications for rapid tooling services. A versatile and dynamic material, silicone can easily be molded to create a cavity or shape according to a master pattern. With the dawn of new prototyping methods, more rapid prototyping models require master patterns. Silicone rubber moulds can be used to create epoxy or urethane prototypes.
The rubber mould creation process comprises the making of a master pattern, completing the pattern for the desired look and utility to be achieved and casting room temperature vulcanising silicone rubber around the master pattern to create the mould. Silicone is a transparent material; the model structure is suspended in a box while the silicone rubber gets poured and fully surrounds the model. Once this material solidifies, you cut the parting line using a scalpel before removing the model. This leaves you with the desired empty cavity.
RTV silicone rubber tooling creates cost-effective and aesthetically pleasing moulds very fast and gives you multiple material options. It works for both small and large parts.
2. Vacuum Casting
Vacuum casting is a tooling service used to make plastic parts. A vacuum chamber filled with a polyurethane resin is fitted with a silicone tool. The resin de-gassed and mixed then poured to fill the silicone cavity. Once poured, the vacuum releases and the component gets removed for about two hours (based on the size) to a post-curing oven. The two-part resin sees an exothermic reaction, after which the cavity opens and one removes the polyurethane part. Then the silicone cavity is closed before repeating the process.
3. 3D Printing
Only recently, tooling service providers have started using additive processes to render rapid tooling services. The key benefit of 3D printing is a higher rate of flexibility than any other tooling service method. Additionally, you don’t need any blanks or physical moulds. You can also make cooling channels and corners that other processes cannot achieve.
4. EDM Tooling
EDM stands for electric discharge machining. It is among the most indispensable techniques of all rapid tooling methods. It is best used when you are working with hard materials for tooling production. Some tools used in the production of titanium alloy components can withstand extreme pressures even during the manufacturing process. So, instead of cutting small chips using the milling center, manufacturers form a reversed cavity on a relatively softer material like copper and aluminum. This is then installed on the EDM machine to complete the product life cycle.
5. Cast Resin
Cast resin tooling is among the easiest and most cost-effective techniques of tooling when it comes to thermoplastic component injection molding. This process needs a manufacturer to get a mould box and mount a pattern within it, set up a part line and then paint it. Later, the resin is poured over this pattern till there is enough material to form half the tool. Once this half is completed, the same process is followed for the other half too. Of all the tooling resins with varied thermal and mechanical characteristics that are available, epoxy is the most widely used one. These resins are usually loaded with pellets or powder of aluminum to boost the tool’s thermal conduction and the strength of compression and bring down the resin’s cost. Cast resin tooling can produce up to 1000 parts, varying based on which material is being molded.
There are several other rapid tooling methods that different tooling companies offer. To know more, choose a tooling services organization that understands your project requirements.
