Integrating rapid prototyping and tooling with vacuum casting for connectors

Connectors are developed to satisfy the needs of advanced technology in telecommunication switching systems and companies have several products designed to fulfil the needs of the many switching networks available. The “Four-wall-header” is one such product from one company. The traditional manufacturing line relies heavily on hard tooling which is both expensive and time-consuming. This paper presents an alternative method of integrating rapid prototyping technologies, in particular, stereolithography apparatus (SLA), with a vacuum casting system to produce a wide range of polyurethane parts. Altogether, three approaches are analysed and evaluated for making the moulds: rapid pattern, rapid tooling and a hybrid approach.