NDM Rapid Tooling Process for Aluminum and Thermoplastic Parts

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

12. Process Comparison:Metal Die Casting

13. NDM Process Steps

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

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

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

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

18. Step 5- Fill Mold • RTV molds filled • Stainless steel powder • Proprietary binder

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

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

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

22. Step 9 – Prep Inserts • Finish inserts and prep for mold base • Rig mold • Load 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 Corporation19 Fifth AvenueCranston, RI 02910sales@bdsales.com401-781-4810Fax: 401-781-5580