Sounds like this may be a good application for the Technicast process.
For those not familiar with it the process goes as follows:
Take a model (usually a hand carved toy)
Replicate with silicon rubber (gives a model of the cavity)
Cast ceramic against the rubber
Cast beryllium copper against the ceramic to produce the tool.
I believe this process came out of the USA but the only contact I have
is here in the UK:
Technicast Moulds Ltd.
Unit 1 Garnett Close
Greycaine Industrial Estate
Hertfordshire WD2 4JL
Phone: 01923 246530
Fax: 01923 255983
Professor Phill Dickens
De Montfort University
Rapid Dude wrote:
> This one needed a push...
> ---------- Forwarded message ----------
> Date: Fri, 24 Apr 1998 15:03:14 -0400
> To: email@example.com
> From: john durden <firstname.lastname@example.org>
> Subject: help
> Dear List,
> We have been asked by one of our customers to
> build a plastics injection mold. That's our business, so
> normally this wouldn't present a problem. The catch,
> here, is that the only data available is a hand-carved,
> full-scale model of the part. The object is of a sculptured,
> multi-faceted, free-form geometry that does not lend
> itself to modeling in a cad package such as Pro/E.
> Casting directly from the model might be an option, however,
> the cavity blocks would be approximately 11" x 7" x 2", so
> we have ruled out Kel-Tool.
> The best option for us would be to have the model scanned
> into some sort of a surface model that we could output to our
> machining center.
> Can someone on this list tell me the best way to approach
> this; or, better yet, scan the object into a useable surface
> model (for a fee, of course).
> Thanks for your help.
> John Durden
> Durden Plastics
> Fax: 770-995-7067
> 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/
For more information about the rp-ml, see http://ltk.hut.fi/rp-ml/
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