Rapid Mould: epoxy-infiltrated, laser-sintered inserts

Describes and evaluates a laser-sintering based method for prototype tooling epoxy-infiltrated, laser-sintered inserts. The niche aimed at is prototype tooling for up to a hundred parts. The results are promising. The method is rather fast where two inserts (one tool) can be made within a week. Shrinking seems to be uniform and less than 2 per cent in x, y, z from green shape to infiltrated part. Surface finish is the main issue that needs further improvement. No design changes due to material properties were made. However, a mother form system for injection moulding was used to hold the insert and was helpful in reducing stresses. In less fortunate situations, a mechanical constraint should be considered. The tool was used for injection moulding; 50 parts were made in polypropylene.