A tool steel for rapid manufacturing with applications to injection mold tooling

Production-grade tooling for injection molding can be made from tool steel powder via the ProMetal 3D Printing solid-free form fabrication technology. This process enables the formation of non-round and non-straight internal channels in the printed part. In application of this process to fabrication of an injection-molding tool, the internal channels can be configured in proximity to the forming surface of the tool to permit rapid and uniform removal of heat throughout the formed part The net result is reduced cycle time and greater dimensional consistency in production of plastic or metal-injection-molded parts. Achieving these benefits requires a tool material having sound metallurgical structure and properties. A modified M4 tool steel has been developed for this purpose. After 3D Printing and debinding, the mold shape is thermally processed by supersolidus liquid phase sintering to achieve nearly full density and desirable mechanical properties.