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

2. 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

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

4. Benefits of NDM

5. Core and Cavity Process yields excellent tool finish Captures intricate detail

6. Core in Universal Base 600,000 shots and still running

7. Cavity Ideal for geometrically complex shapes

8. 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

9. 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

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

11. 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.

12. 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.

13. NDM Process Steps

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

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

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

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

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

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

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

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

22. 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

23. Step 10- Run Parts Cavity mounted in mold base

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

25. Step 11- Finish part Raw casting with runner still attached

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

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

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

29. 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

30. 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

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

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

33. Injection Molded Plastic Plastic- Noryl 873

34. MIM- Metal Injection Molding Nickel/ Steel Alloy

35. Questions www.armstrongmold.com Paul Armstrong - sales@armstrongmold.com John Mathews - jmathews@armstrongmold.com

36. To Obtain Information Regarding The Licensing of The NDM Process Contact: B&D Sales Corporation 19 Fifth Avenue Cranston, RI 02910 sales@bdsales.com 401-781-4810 Fax: 401-781-5580 sales@bdsales.com