Thank you to all who responded,
More Info:
I have a part that is 10"x4"x2" with 5 seperate angled core pulls that
must intersect.
Many of the cored areas need to seal o-rings and contain pressurized
gasoline. We can often impregnate machined parts for prototypes, but
we want to keep the skin of the casting intact to avoid porosity in
the production die cast parts.
I designed this to shoot in A-380 aluminum, and what I am looking for
is 100-250 good castings to use for internal engineering testing as
well as regulatory testing while the production multi-cavity tool is
built.
My production quantities are 175,000-250,000 per year so I need to
build a hefty tool.
Results so far listed below... Anyone with any other good ideas?
Larry Blasch
Design Engineer
OPW Fueling Components
Cincinnati, OH 45240-5003
Voice: (513) 870-3356
Fax: (513) 874-1231
e-mail: lblasch@opw-fc.com
********************************************************************
Here is a list so far:
********************************************************************
Larry, give me a call. We handle the logistics of RP masters through
plastercasting at the foundry.
Bob Powell
Account Executive
Accelerated Technologies, Inc.
12919 Dessau Rd.
Austin TX,78754 USA
fax:512-990-9726
voice:512-990-7199
email:bpowell@atiaustin.com
********************************************************************
Larry: Simply send a zipped binary .stl stating the production
quantities anticipated and we will quote your needs for precision cast
prototype and production parts in zinc (zamak 3, 12 or 27) or
aluminumm alloys (A356, D712) from your patterns or ours.
Best Regards,
Tom Richards, Metallurgist
tomr@aicasting.com
********************************************************************
Larry, there are few methods we use to create castings (Invest
Casting):
1. Direct from QuickCast patterns.
2. RTV Tool and Plastic Patterns.
3. Epoxy tool and wax patterns.
4. Casting using RPM method.
Please send us an STL or IGES Surface file along with the quantity you
have in mind. I need to know more about the geometry to tell which
method provide the best results. Regards,
Gary Vassighi
3D-CAM, Inc.
9139 Lurline Ave.
Chatsworth, CA 91311
Phone: 818-773-8777
FAX: 818-773-0979
http://www.3d-cam.com
Gary@3D-CAM.com
*******************************************************************
Larry, Bastech in Dayton, OH has used SLS Rapid Steel to make die cast
tools for prototype quantities of zinc & Al parts. Contact Ben Staub
at 937-890-9292
*******************************************************************
Larry;
I have had quite a few inquiries about this subject. I come from a
Diecast
background. I've been building molds my entire life and now I'm too
old to get a real job. The company I worked for previously is the
biggest independent diecaster in the USA Top Diecast Co ( a real nice
bunch of people). With them I had my first experiences with the 3M
Tartan ( now 3D Keltool) 20 yrs ago or so, doing mostly Diecast. It
appears everyone in the Diecast industry has the same problem getting
manufacturing equivelent prototype parts. They all tell me that the
investment cast parts which they can get do not have the same
mechanical properties and cannot be used for certifications. I have
attempted to do pourings of Zamak 3 zinc into high temperature
silicone molds. Fusion Engineering shares a building with a zinc
diecaster so I have an endless supply of molten zinc. I was attempting
to mold very thin walled highly detailed prototypes for a product
which I cannot describe. They wanted it in magnesium but the
prototypes could be zinc which is much safer to work with. Needless to
say we were unable to pour acceptable parts. the zinc freezes to
quickly even in silicone. I did however learn a great deal from the
experience (mostly how to treat burns and what not to ever try again).
What we did learn is that metals have to be injected at great speed
thus requiring an injection molding machine ( I already knew that but
I had to try it anyway). We did however figure out a way to make zinc,
magnesium, or aluminum short run parts inexpensively by utilizing our
3D Keltool process. What our customers do is, most Diecasters have
standardized moldbases on their shelves that they use for tryouts and
quick change applications, usually one for each size range. Lets say
the pocket size is 1.5 x 3 x 6. they have all the runners and
spreaders installed already at a standardized location. What they then
do is order Keltool inserts from us. If it is a real low volume we
eliminate all the holes and core pins they can be drilled later. If
there are any slides required we eliminate them also and CNC machine
the details in later. We then build very simple keltool cavities made
right to the finished dimensions (no finishing stock anywhere) so the
inserts can be immediatly dropped into the die shoe. We grow the
runner fan and overflows right into the keltool blocks sometimes we
even include the ejector pin holes so the only machining required is
the tapped holes to hold the blocks down in the pocket. This process
seems to be working very well. Either us or any 3D keltool supplier
(hi Brad) can supply these types of cavities in about 10 days. the
cost is around $30 per cubic inch and a some change (excluding SLA
masters and Engineering of course) Cavities to fit the above size 1.5
x 3 x 6 will cost $2600 dollars we couldn't care less what your part
looks like. It can be simple, complex its all the same to us if it
fits within those blocks its $2600 bucks. If we have to Engineer the
parting lines and model the blocks then grow the SLA cavities and
cores this usually comes out to a similar amount, less if the part is
simpler. Of course If you can supply a master part with the part
shrinkage and the .006 Keltool shrinkage we can jam it into a lump of
clay to form the parting lines. This will cost you a little less but
its a pain and not as accurate. We prefer the CAD method. We can work
with any type masters not just SLA.
I would expect in aluminum you can get maybe 300-500 good parts with
the quality deminishing thereafter (heat checks). In magnesium maybe a
thousand. In zinc we have one that has over 30,000 shots and its still
going strong we guaranteed it for 50 thousand ( I still have my
fingers crossed). These are all of course un-heat-treated A6 keltool
material. You could probably get many more if you heat treat the
cavities and treat the cavities with a ferritic nitrocarborizing
process (maybe as much as 10 fold). Currently the size limits are
about 5 x 6 x 9 for any single blocks but they can be jammed together
for larger parts. The published accuracy of the 3D keltool cavities is
+/- .002inch / per inch. None of this is new technology or even high
tech. All this has been around for 20 some years (pre-dates RP ) so it
is out of favor these days. The only new twist is the ability to make
the SLA master cavities complete and ready to go in a day or so thanks
to our friends at 3D who have been quietly perfecting their technology
so it can be used in the mainstream manufacturing environment. I'm
really pumped on what we will be able to do in the future as all this
develops even more. But lets not forget the tried and proven past in
our zeal for high technology, which in my opinion many of us are way
too hyped upon (myself included).
Good luck
Bob Morton
Fusioneng@aol.com
For more information about the rp-ml, see http://ltk.hut.fi/rp-ml/
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