Car Mock-ups are Important Basis for the Automobile Industry

In the car production, more than 90% of the parts need to rely on mold forming. For example, the most basic front and rear headlights, bumpers, car trim, etc., are under the help and auxiliary of rapid prototyping.

China’s automobile rapid prototype industry closely follows the development of automobiles, and whether in technology or equipment, should focus on product structure adjustment, and gradually enhance the level of rapid moulding, which is believed to be the prerequisite to occupy the high-end market with complex prototypes with complex structure, high precision and advanced technology.

The basic idea of the development of automobile rapid prototyping model industry and technology highlights the development lifeline and mileage of a business.

Development as the theme and market, reform and technological innovation as the driving force, KAIAO, one of the top rapid prototyping company in automobile moulding industry in China, gradually grows into a strong mold enterprise with international competitiveness. Under the national industry policy, KAIAO vigorously promotes the industry organizational structure optimization and upgrades of industrial structure, accelerate the development of the market much-needed key products.


The Era of Personalized 3D Printing for Medical Treatment Is Near

With the booming of 3D printing all over the world, 3D printing organ has become a real tool available. 3D print chest, nutcracker syndrome, skull and so on are the real application in medicine. The practical prospects of 3D printing in the medical model, prosthetics, dental surgical template, skull, cervical vertebral body and artificial joints and other aspects are great with great advantages in practicability and fungibility.

At present, the application of 3D printing technology has indeed been clinically recognized. 3D printing is able to offer the difficult and unpredictable disease with a treatment or further improve the treatment, so as to improve the treatment effect.

Therefore, the development of personalized and customized medical care is necessary. Through these organ models for preoperative simulation exercises, to develop a personalized surgical program, is able to avoid some unexpected situations. At the same time, treatment can be “personalized and customized”, which avoids the unnecessary surgical openings and greatly improve the recovery quality for patients and speed up the healing time.

In order to better apply 3D printing technology to the medicine and medical fields, such as the introduction of 3D printing pills, 3D print implants, 3D printing organs and organizations. KAIAO is striving to make custom 3D printing technology internationally standardized, gradually, and is continuing to develop relevant guidelines for better use of 3D printing technology for medical enterprises and individuals to provide better customized services.

Is CNC Prototype Machining Still the Mainstream in Five Years?

As a professional team in mock-up sample industry for over a decade, KAIAO thinks that, as an  advanced product of industrial revolution, intelligent CNC technology combines a variety of mechanical and electronic advanced technology and has been in a relatively mature technology stage. Relying on this technology , the important production equipment -CNC engraving and milling machine plays an important role in the entire production process. CNC prototype machining can rivals mold making in accuracy, up to about 0.02.

In one of our cases for bearing aluminum alloy CNC prototypes, we meet the customer requirements and do the accuracy to 0.01-0.02 to be a perfect match. Considering shrinkage factors in mold injection molding, CNC prototype machining is possible to be more accurate than injection molding.

In the next five or even ten years, KAIAO, one of the top CNC prototype machining companies in China, still believes that CNC Machining is the mainstream for rapid prototyping. As an industry elite team, KAIAO has been concerned about the prototype industry development, so as to continuously improve the technical content of prototypes and provide thoughtful service, leading industry development for more customers.

Advantages of Aluminum Prototyping

First, aluminum prototypes not only select high quality materials, but also produced by professional production and processing center. The most significant advantage of aluminum prototyping is reflected in the rapid production. In addition, in the production process, the wall thickness of the product also has a certain standard requirement, if the wall thickness is too thin, the product cannot be produced.

Second, due to the special selection of materials, prototype aluminum casting accurately reflects what the pre-designed product drawings want to express. Not only that, the surface quality is also very good, especially after silk screen and related surface spray processing, the product looks exquisite and glory.

Indexable Cutting Tools

In the CNC machine cutting process, when a cutting point is blunt, it will no longer be re-grinded and will be transposed with another cutting point. Most cutting point of the indexable cutting tools uses carbide as well as ceramic, polycrystalline cubic boron nitride or polycrystalline diamond.

During 1949 to 1950, the United States first developed a mechanically clamped tool, and in 1954 began to sell the so-called throw-away indexable inserts.

Advantages of Indexable Tooling

Due to the high efficiency and little auxiliary time of indexable tooling, it greatly promoted the advancement of CNC tooling.

The indexable cutting tools has the following advantages compared to brazing and other mechanical clamping tools:

1.Avoid the shortcoming of hard alloy brazing’s prone to crack
2.Indexable inserts is suitable for vapor deposition on the surface of cemented carbide blade thinner harder materials (titanium carbide, titanium nitride and aluminum oxide) to improve the cutting performance
3.Indexable tool changing time is shorter
4. Stable chip control due to the standardized and centralized production of indexable cutting tools. Blade geometry is easy to match.

Indexable tooling Applications

Indexable tooling is widely used in various turning tools, boring tools, milling cutters, outer surface broaches, large diameter deep hole drilling and nesting drilling.

Make full use of indexable cutting tools’ advantages

Due to the advantages of indexable tooling discussed above, KAIAO, one of the top CNC machining companies, uses indexable cutting tools in its CNC machining for the customers and it is fully experienced to take full advantageous of the indexable inserts.

If you are interested in using CNC machining as your next project, KAIAO is going to be of great help. Feel free to contact KAIAO for a free quote.

Rapid Tooling and Types of Rapid Tooling

Since produced in the late 1980s in the United States, RT tooling has rapidly developed and widely used in the whole industry, making it in a prosperous stage of development. Rapid Prototyping Manufacturing technology, if stays in the prototype production, will not form an impact to the manufacturing. The prototype of Rapid Prototyping Manufacturing technology in many cases is not a substitute for the final real product due to its materials used.

Rapid Tooling

In order to obtain products produced by real materials and form a certain amount of production capacity, Rapid Tooling (RP Tooling) comes into being based on Rapid Prototyping Manufacturing technology. In order to play a greater advantage of RPM technology, it must form a certain amount of rapid manufacturing capacity, therefore, Rapid Tooling, which is based on RPM rapid die technology, is now in rapid developing.

RT tooling is characterized by its significant economic benefits, which reduces about 10%-30% when compared with the traditional CNC machining.

Types of Rapid Tooling

There are two types of rapid tooling based manufacturing methods: direct rapid tooling and indirect rapid tooling.

Direct rapid tooling uses RT tooling to produce molds directly. Among the methods and types of rapid tooling, selective laser sintering, which is short for SLS, can directly produce the metal mold. Steel and copper alloy injection mold manufactured by direct rapid tooling can be used up to 50,000 or more. However, in the sintering process, materials shrink and it is difficult to control, making it hard to get high precision mold quickly. At present, the major type of rapid tooling is indirect rapid tooling. And, according to the different materials, indirect rapid tooling can be generally divided into Soft Tooling and Hard Tooling.

KAIAO Rapid Tooling

KAIAO Rapid Manufacturing Co.,Limited specialises in rapid prototyping like rp tooling and always offers customers the best parts with high accurate in short time with low cost because of decades of experiences and always full advantages of rapid CNC machining, RIM, RT tooling taken. Both plastic prototypes and metal molds are be easily handled by KAIAO. If you are interested in RP tooling to make your next project, feel free to contact KAIAO for a free quote.

A better way to produce hundreds of thousands of pieces

The number of products soft tooling can produce is generally 50-5000 pieces, for tens of thousands or even hundreds of thousands of products, we still need the traditional steel moulds. Hard tooling refers to the steel mold. The main methods using RPM prototype for steel moulding here in KAIAO are as follows: investment casting, Spark Erosion Machining , ceramic-type precision casting.

Below we will also show you a brief introduction to those methods and its basic process as well as the advantages and suitable projects. If you are interested in using those as your next project, KAIAO, as one of the top hard tooling companies in China, will surely be your top choice. Feel free to contact KAIAO here for a free quote.

Spark Erosion Machining

Spark Erosion Machining uses RPM prototype to produce EDM electrode, and then produce steel mold by spark erosion machining, the basic process is generally as follows: RPM prototype-three-dimensional wheel-graphite electrode-steel mold.

Investment Casting

Investment Casting can be used in the mass production of steel moulds, which uses the RPM prototype or soft tooling based prototype to produce wax patterns and then use the investment casting process to produce steel mold. Almost all RPM prototypes can be used as a die for precision casting.

Ceramic Precision Casting

For single or low volume production of steel mold, we can use Ceramic Precision Casting. The process is: RPM prototype as the mother mold-dip ceramic mortar- solidify mold shell in the roasting furnace -burn the mother mold-preheat mold-pouring steel mold cavity-cavity surface polishing.

How to Select CNC Milling Tools in CNC Machining

The popularization of CNC engineering technology will make great within modern manufacturing technology. The numerical control rate is a crucial mark of the modernization level of national manufacturing industry. The development of COMPUTER NUMERICAL CONTROL machining technology has a direct impact on the advance of manufacturing technology in various sectors of the national economy.

CNC Cutting Equipment in CNC Machining

Finding out tools for reducing is under the man-machine interaction programmed by NUMERICAL CONTROL. The CNC machine slicing tools and handles should be selected appropriately structured on the processing capacity of the machine, the fabric performance of each workpiece, the processing techniques, the cutting amount and other related factors. The general principle of COMPUTER NUMERICAL CONTROL milling tools selection is: easy to install and adjust, good rigidity, toughness and finely-detailed. On the premise of meeting the processing requirements, make an effort to choose a shorter handle to increase the rigidity of CNC milling cutter tooling.

In digesting the free surface of CNC machining, there is no cutting speed in the head of ball end cutter, therefore, in order in order that the processing reliability, cutting line spacing is generally made close, and the ball head is often used for surface finishing. The flat brain tool in the surface processing quality and slicing efficiency are better than the ball knife, so, in the premise that no over cutting is guaranteed, KAIAO always give priority to the choice of flat knife for both rough surfaced control and finishing.

In addition, the toughness and accuracy and reliability of CNC milling tools is extremely relevant to the tool price. That must be noted that, in most cases, the choice of good tool increases cost, nevertheless , KAIAO are always able to associated with whole refinement costs reduced for you with better CNC machine cutting tools selected as they are incredibly helpful to improve processing quality and efficiency.

CNC Cutting Tool Selection and Cutting Amount Determination

The selection of the tool and the determination of the cutting quantity are the important contents in the numerical control processing technology. It not only affects the processing efficiency of the CNC machine tool, but also directly affects the processing quality. The development of CAD / CAM technology makes it possible to use CAD design data directly in CNC machining. Especially, the connection between computer and CNC machine tool makes the whole process of design, process planning and programming all done on the computer and no special craft documents needed any more.

Now, many CAD / CAM software packages provide automatic programming functions, which are usually in the programming interface and prompts the process planning issues, such as tool selection, processing path planning, cutting the amount of settings. The programmers only have to set the parameters and NC programs are automatically generated  and transferred to the CNC machine to complete processing. Therefore, the choice of tool selection and cutting in numerical control machining is done in the form of human-computer interaction, which is in sharp contrast to the common machine tool processing. It also requires the programmer to master the basic principles of CNC cutting tool selection and cutting programming to fully consider the characteristics of CNC machining. In this post, the problem of tool selection and cutting quantity determination which must be faced in NC programming is discussed. Some principles and suggestions are given, and the problems that should be paid attention are discussed as well.

Types and characteristics of CNC Cutting Tools

CNC machining tools must meet characteristics of CNC machine:high speed, high efficiency and high degree of automation. Generally there are general-purpose tool, universal connection handle and a small amount of special handle. The tool holder is connected to the tool and mounted on the machine power head, so it has been standardized and serialized.

There are several ways to classify CNC tools. According to the structure, CNC cutting tools can be divided into:

  • integral type;
  • mosaic, by the use of welding or machine folder connection, it can be divided into non-transposition and indexable two;
  • special type, such as compound cutter, Vibration tools and so on.

According to the material used to make the tool, tools for cutting can be divided into:

  • high-speed steel cutting tools;
  • carbide cutting tools;
  • diamond tools;
  • other materials, such as tools, such as cubic boron nitride tool, ceramic cutting tools.

From the cutting process, CNC machine cutting tools can be divided into:

  • turning tools, sub-circle, hole, thread, cutting tools and other;
  • drilling tools, including drill, reamer, taps, etc .;
  • boring tools;
  • Milling tools

In order to meet the requirements of CNC machine tools to be durable, stable, easy to adjust, easy to be changed, in recent years, machine-type indexable tool are widely used with about  30% to 40% of the entire CNC cutting tools and 80% to 90% of the total metal removal.

Characteristics of CNC Cutting Tools

When compared with general-purpose machine tool, CNC cutting tools have the main characteristics as follows:

  1. good rigidity (especially roughing tool), high precision, anti-vibration and thermal deformation of small;
  2. interchangeability is good, easy for quick tool change;
  3. high life, cutting performance is stable and reliable;
  4. The size of the tool is easy to adjust to reduce the tool change time;
  5. The tool should be able to reliably break the chip or chip, in order to facilitate the removal of chips;
  6. series, standardization, in order to facilitate programming and tool management.

The choice of CNC machining tool

When selecting CNC cutting tools, KAIAO, one of the top CNC machining companies in China, is fully experienced and always makes sure the size of the tool matches the surface size of the workpiece. In the production, while tooling the peripheral parts of the contours in KAIAO’s CNC machining factory, KAIAO often uses end mills; While milling plane, we select carbide cutter cutter and high-speed steel end mills for processing boss or groove. For rough surface or rough holes, corn cutters with carbide cutter blade are selected. Besides, the CNC milling cutters like ball cutter, ring cutter, tapered cutter and disc cutter are used for some three-dimensional profiles and variable bevel contour contours.

For more details, please visit: How to Select CNC Milling Tools in CNC Machining.

How to determine the amount of cutting

The principle for a reasonable choice of cutting amount is that, in rough processing, we generally need to improve productivity-based, but should also consider the economy and processing costs; in semi-finishing and finishing, we should ensure the quality of processing and take the cutting efficiency, economy and processing costs into account. The specific values should be based on the machine manual, cutting the amount of manual, combined with experience.