Rapid Tooling

Question 1

What is rapid tooling?

Answer 1

The process in which conventional tooling processes are combined with rapid tooling processes to produce a mould or pattern quickly and at a lower cost relative to traditional manufacturing methods

Question 2

Why use rapid tooling methods?

Answer 2

Good for high complexity 
Good for short runs
Effective for prototyping
Suitable for high value products 
Encourages new product innovation

Question 3

Why not just print the part instead of rapid tooling?

Answer 3

Too slow

Question 4

What are the differences between direct and indirect tooling?

Answer 4

Direct
Direct production of a tool from sliced CAD data (cheap/polymer)

Indirect
Production of a master or pattern from which the tool is produced (used when tool is a different material/ harder wearing)

Question 5

Examples of polymer processes that use moulds and dies

Answer 5

RTV casting (cheapest)
Injection moulding (highest tooling cost but good for high volume)
Vacuum forming (in between, still relatively cheap)

Question 6

Examples of metal manufacturing processes that use moulds/dies

Answer 6

Forging (old method)
Stamping 
Casting (high pressure and heat)
Pressure die casting
Gravity die casting 
Investement casting etc...

Question 7

Benefits of direct rapid tooling?

Answer 7

Higher geometrical complexity (conformal channels)
Functional coatings (hard wearing surface, thermally conductive, heating/cooling channels)
Possibility of more design iterations

Question 8

How is rapid tooling used for bespoke medical devices?

Answer 8

Liquid casting of polymer materials such as RTV silicone allows the low volume production of unique parts made from required material properties

Question 9

what is a commercial example of a brand that uses rapid tooling and how?

Answer 9

Invisalign

Not contact scanning
Moving teeth calculated
Moulds printed by SLA (toxic, can't go into mouth, not many biocompatible resins available.)
Vacuum forming
Patient wearing it

Question 10

How does rapid tooling work for investment casting? And what industry is this used in?

Answer 10

3D model
Wax 3D printing of object, layer by layer
Build mould around wax object (ceramics)
Melting wax and remove it
Fill empty space with molten metal

Question 11

How does Quick Cast improve rapid tooling?

Answer 11

Builds SLA part as a shell supported by an internal honeycomb structure
Reduces weight and cost