Rapid tooling of die DMLS inserts for shoot-squeeze moulding (DISA) system

The rapid tooling (RT) technology applied to die-plates for moulding in DISAmatic(C) cast line was investigated. Die inserts made by RT direct techniques such as: direct metal laser sintering (DMLS); stereolithography (SL); laminated object manufacturing (LOM); and selective laser sintering of polymer powder (SLS-P), are compared. Mechanical properties and accuracy are critical on choosing the rapid tooling die inserts as the production-grade tooling. The main goal of this paper is to introduce the ability of direct metal laser sintering in producing metal tools directly from computer aided design (CAD) data. The DMLS process is established in rapid tooling, since a suitable sintered metal powder can be used to produce the foundry tools. The properties of the DMLS tools, however, depend on powders composition and sintering conditions. The DMLS powder material system utilised is a mixture of nickel, bronze and copper-phosphide. This study includes the dimensional accuracy comparison of RT die inserts, which are fabricated by DMLS, SL, LOM, and SLS-P techniques. Some conclusions are reached at final about rapid processing techniques indicating the advantages of reducing manufacturing time and achieving an acceptable die precision, and suitability for a wide application in making the metal die of DISAmatic(C) cast line. (C) 2004 Elsevier B.V. All rights reserved.