On Demand Manufacturing and Rapid Prototyping are relatively new technologies that have generated significant excitement and accelerated product development. These technologies have had relatively little impact on the tool and die industry however, due to the fact that there are few (if any) techniques that produce items with acceptable strength and surface finish. Over the past decade BFD, Inc. has developed a unique material family and near-net shape processing profile (ONNEX technology). These materials have not been tested in tool applications, but based on measured high hardness, fracture toughness and thermal conductivity they should be excellent for this application. This technology shows promise for: Rapid die turnaround (design to use in days instead of weeks), Substantially lower die costs, Die life competitive with tool steels, Improved heat extraction compared to tool steel due to: - higher thermal conductivity, - optimal cooling line placement, This proposed work will focus on development and optimization of critical process technology necessary for demonstrating the applicability of ONNEX technology for tool and die applications. Phase II will further apply this technology to functional prototypes for use in commercial environments. If successful this technology should revolutionize the tool and die industry. Anticipated Benefits/Commercial Applications: Successful development and demonstration of ONNEX tooling for use in the plastic and metal forming industries will greatly change the fundamental rules defining these industries. ONNEX tools and dies have distinct advantages over existing tooling technology and exhibit the following characteristics: Rapid die turnaround (design to use in days instead of weeks), Substantially lower die costs, Die life competitive with tool steels, Improved heat extraction compared to tool steel due to: - higher thermal conductivity, - optimal cooling line placement. ONNEX tooling will allow more frequent design changes in metal and plastic parts to accommodate frequent model changes, and low-volume production runs enabling short lifecycle products to be marketed. These advantages will drive additional market entry opportunities with strategic partners and customers who want to exploit these valuable benefits in multiple market segments. Furthermore, tooling amortization will be lower, increasing the competitiveness of manufacturers who use these tooling systems and allowing the U.S to once again become competitive in the tooling market.
Keywords: Rapid Tooling Composite Ceramic-Metal Tool Die Near Net Shape
