ISF rapid tooling applications

Abstract

The use of sheet metal tools finds its main applicability for processing thermoplastic and thermoset materials, in which the moulding loads and temperature are low. ISF rapid tools have their core parts formed by incremental processes taking advantage of the free-form capability and flexible manufacture. Other complementary operations are used to finish the tools in a fast and low-cost way. A reference geometry has been used to design a set of parts to be manufactured using different manufacturing processes. All parts were detailed to allow a feasible manufacturing process, including the addition of radius between sides and other design features in some walls. The distinct shapes are used in hand moulding operations, vacuum forming, rotational moulding and compression moulding. The proof of concept tests validates the direct rapid tooling techniques using incremental metal forming, although they also confirm the course accuracy reachable which influence the method selection. The tests use a highly available and low-cost 1050 aluminium alloy with 2 mm thickness. This material limits the maximum loading to a significantly low value, although it proves to be adequate for the moulding operations.