Re: Looking for Die cast prototypes from rp masters

From: Michael Tsenter (nest@primenet.com)
Date: Mon Sep 13 1999 - 18:22:05 EEST


Hi Larry:

You may want to consider our PRECICAST ceramic/sand casting process that
has been specifically developed for prototyping and "bridge" production
of complex metal parts that are normally die cast.

This process does not use RP masters, but instead we machine tooling on
a high speed CNC machine using high-density plastic material. (This
takes 1-3 days)

Every project starts with a comupter simulation to eliminate porosity,
predict areas of "cold shut", and compensate for liquid shrinkage. At
the end, of the process our "fluidized bed" 3-stage heat treatment
process is applied to optimize mechanical properties and minimize
distortions.

At this time we only cast aluminum (any alloy). Our production capacity
is 30 molds per hour, so 250 parts can be done in 1 day. Typical
delivery schedule from receipt of CAD data is 4-5 weeks. The tooling
will last for up to 50,000 parts.

The following table compares mechanical properties for typical alloys.
(Note: A359 is very similar to A356 except it has a little more
magnesium in it)

                Tensile Strength Elongation Brinell Hardness
                kPSI (N/mm2) A - % HB

380 Diecast 35-45 (240-310) 0.5 - 3 80-120
359 Precicast 32-46 (220-320) 1 - 3 80-110
380 Precicast 23-29 (160-200) 1 - 3 65-90

Below is the table outlining process capabilities:

Linear Tolerance: ± 0.008" on 8"
Repeatability: 0.006" average
Minimum Wall Thickness: 0.080" - 0.120"
Minimum Diameter of Cast Holes: 0.160"
Depth of Cast Holes: 3x - 5x diameter
Maximum Height of Pins & Fins: 2.5"
Minimum Draft Angle: 0 - 0.5 degrees
Surface Finish: 150 - 175 RMS
Hardness: 41 - 64 Rockwell B
Maximum Mold Size: 35" x 27" x 28"
Production Capacity: 30 molds per hour
Tooling Life: up to 50,000 parts

We can quote your project if you send us either STL or IGES file. If
you use Pro/E or SDRC, we can use your data directly.

Please let me know if you would like to receive a video tape showing our
foundry along with a detailed technical description of the process.

Sincerely,
Michael Tsenter

----
NEST Technologies, Inc.
3849 Ridgemoor Drive
Studio City, CA 91604 USA
Tel:	818-761-6500
Fax:	818-761-6116
e-mail:			nest@primenet.com
web site:		http://www.primenet.com/~nest

> > Dear List, > > First I checked the RP-ML Archives and I found a few leads, but I am > looking for current data. > > I am looking for sources that can make me Aluminum and Zinc/Aluminum > castings from rp masters with plaster or silicone molds to replicate > die cast parts. I am attempting to create "Manufacturing Process > Equivalent" parts for agency certification testing. > > If you can suggest another way to produce die castings without costly > tooling, I would like to hear from you. > > Thanks in advance, > > 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 > > For more information about the rp-ml, see http://ltk.hut.fi/rp-ml/ > > For more information about the rp-ml, see http://ltk.hut.fi/rp-ml/

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For more information about the rp-ml, see http://ltk.hut.fi/rp-ml/



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