NDM Rapid Tooling Process for Aluminum and Thermoplastic Parts Paul Armstrong John Mathews

NDM Process Patented program –Owned & licensed by B&D Sales Corporation Under development for several years –Continuing R&D for improvement Armstrong Mold and B&D Sales working jointly to: –Increase the number of applications –Expand industries that can utilize this procedure

Topics Benefits of NDM Design considerations Process steps Case study Where do we go from here??

Benefits of NDM

Core and Cavity Process yields excellent tool finish Captures intricate detail

Core in Universal Base 600,000 shots and still running

Cavity Ideal for geometrically complex shapes

Benefits Versatility –Die casting –Thermoplastic injection molding –MIM (metal injection molding) Fast turnaround, low cost – 2 weeks from CAD file to part Mold hardness –Extended tool life Quick cavity duplication –Ideal for multi-cavity molds

Design Considerations Cavity/Core insert size –1” x 1” x 1” to 4” x 6” x 2” Complex angular/curvaceous shapes Part materials –Aluminum –Most thermoplastics –Most MIM materials Draft angles –Industry standards with radii and fillets

Design Considerations Wall thickness –Die casting industry standards –Injection molding industry standards Tool life –Prototype quantities to 100,000+

Process Comparison : Injection Molded Plastics Lead Time (Wks) Tool LifeCostHeat Transfer Cavity Finish M/C AL4-5FairLowExcel.Good M/C Pre- hard 5-6GoodMedGood M/C Hardened 6-7Excel.HighGoodExcel. Cast AL3-4FairLowExcel.Good Cast Kirksite3-4FairLowExcel.Good NDM2-3Excel.LowExcel.

Process Comparison: Metal Die Casting Lead Time (wks) Tool LifeCostHeat Transfer Cavity Finish M/C Pre- hard 5-6GoodMedExcel.Good M/C Hardened 6-7Excel.HighExcel. NDM2-3Excel. ?LowExcel.

NDM Process Steps

Step 1 – Engineering Review Prep of e-modelPrep of e-model –Add shrink –Add draft

Step 2 – Build Pattern Create master modelCreate master model –SLA –CAM

Step 3 – Rubber Mold Create patternCreate pattern –Negative impression from master –Using RTV

Step 4 – Prepare Mold Treat rubber mold with mold releaseTreat rubber mold with mold release

Step 5- Fill Mold RTV molds filledRTV molds filled Stainless steel powderStainless steel powder Proprietary binderProprietary binder

Step 6 - Baking Green work piece is bakedGreen work piece is baked Removes liquid binderRemoves liquid binder

Step 7 – Furnace Cycle Work piece is heated in vacuum furnaceWork piece is heated in vacuum furnace Burns off binderBurns off binder

Step 8 - Infiltration Infiltrate with bronze to full densityInfiltrate with bronze to full density

Step 9 – Prep Inserts Finish inserts and prep for mold baseFinish inserts and prep for mold base Rig moldRig mold Load into die cast machineLoad into die cast machine

Step 10- Run Parts Cavity mounted in mold base

Step 10- Run Parts Core with ejector pins out Note gates and runners

Step 11- Finish part Raw casting with runner still attached

Step 11- Finish part Casting – both sides Runner now removed Part ready for de-flash

Step 12- Finished Part Finished part –Machined in tight tolerance features –Satin Nickel Chrome Plating <.001” thick

Case Study - Camera Housing Initial prototyping –SLA –CNC hogouts DFM analysis –Improved casting design RPM casting –Initial 20 prototypes –Aluminum (functional)

Case Study - Camera Housing Product development refinement cycle –3 revisions –Samples via RPM Bridge to production –RPM for 4000 parts RPM cost –Tooling: $5,000 –Casting: $19.85 each

Case Study- Camera Housing CAD to usable die-cast parts –NDM in only 4 weeks NDM cost –Die: $12,000 –Casting: $3.30 each Tool payback/breakeven –725 pieces Ramp up –RPM:100 per week per tool set –NDM:1,000’s per week

Where do we go from here? Larger parts Faster turnaround Compete with off shore and others for production applications

Where do we go from here –Apply to other processes MIM-Metal Injection Molds Thermoplastic Injection Molds Investment wax tools

Injection Molded Plastic Plastic- Noryl 873

MIM- Metal Injection Molding Nickel/ Steel Alloy

Questions Paul Armstrong - John Mathews -

To Obtain Information Regarding The Licensing of The NDM Process Contact: B&D Sales Corporation 19 Fifth Avenue Cranston, RI Fax: