Discussion on Epoxy Mold by Rapid Prototyping

In epoxy moulding, there are a variety of processing methods developed according to the cost, materials, precision requirements, batch etc. Experts say the current rapid tooling methods are roughly indirect molding and direct molding. The method based on rapid prototyping is mainly indirect molding and the mold produced are bridge tooling and soft mold and hard mold.

Bridge tooling usually refers to the direct injection molding of epoxy resin mold. When compared with traditional injection molding, epoxy moulding costs only a fraction of the traditional method and the production cycle is also greatly reduced. The die life, up to 1000 ~ 5000 pieces, is shorter than steel hard mould, but it is longer than the silicone molds, which makes it possible to meet the needs of small and medium volume production.

A lot of enterprises in Shenzhen, the center of moulding in China, has made a lot of progress in the rapid tooling. KAIAO, as one of the star enterprises in rapid prototyping, has accumulated a wealth of experience and establishes a long-term relationship Foxconn, Chana Auto, Motorola etc. and are winning more customers

Generally, rapid prototyping uses solid model (master mould) to copy (such as metal spraying, electroplating, composite casting, casting, etc.) to quickly create the main mold parts (convex, die or mold cavity, core), and its manufacturing cycle is about 1/5 to 1/10 of CNC machining, while the cost is only 1/3 ~ 1/5.

Rapid Tooling is the bottlenecks and key that restrict the development of China’s automobile, home appliances, light industry and other industries. With the continuous development and improvement in hardware and software equipment of rapid prototyping, the strength and accuracy of parts from rapid prototyping continues to improve. Rapid Prototyping has been gradually deep into the field of rapid tooling. Simple economic fast molds based on rapid prototyping specially epoxy mould has become a hot topic.

Epoxy mold is more and more widely used and further promotes the rapid development of rapid tooling, which also helps new research and development in cars and home appliances on the market.

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.

Electroplating in Rapid Prototyping Model Making

Electroplating in Rapid Prototyping Model Making

Electroplating is a process, according to electrolytic principle, that coats a thin layer of other metals or allows over some metal surface, which forms a thin coherent metal coating attached to the surface to prevent meal oxidation (such as corrosion), improve wear resistance, conductivity, opacity, corrosion resistance (copper sulfate, etc.) and enhance the role of aesthetics.

Electroplating in Rapid Prototyping Model Making

While we are doing the rapid prototyping, we are required to add plating effect to the prototypes. However, not all the materials can be plated. Generally, materials that can be plated are ABS, and of course, parts from vacuum casting can be plated as well. Prototype models made by SLA is not suitable for plating, even you do it, the effect is poor.

ABS pieces from CNC machining will get better results if they are electroplated.

Vacuum plating is a method of forming a metal film on the prototype surface by heating, melting, and cooling under high vacuum. TE-PVD is suitable for Al, gold and the like.

Vacuum plating parts must be pieces from overall processing. Otherwise the surface plating will be very ugly if there are bonds.

Because the plating is generally used as the surface sputtering, mainly the inner surface (anti-EMI, but also for small pieces to do the surface treatment, like some keys) relative to the water plating thick film thickness is about 0.01-0.02MM or so, vacuum sputtering of the film thickness 0.005MM.

Pretreatment of Electroplating

Pretreatment, the treatment before plating, includes the following work that needs to be well done:

1. Wash: remove the oil, fat, abrasive, and sludge on the metal surface. Spray, solvent wash, immersion washed or electrolytic wash are common ways to do so.
2. Cleaning: use cold or hot water to wash the residual detergent or dirt.
3. Acid leaching: remove rust or other oxide film. What should be paid attention to is to prevent the substrate being corrosive or produce hydrogen embrittlement. Inhibitors can be added to avoid excessive acid leaching. A full clean is required after the acid leaching.
4. Activation: promote the adhesion of the coating with a variety of acid solution to activate the metal surface.
5. Drift: immediately remove acid film and then plating

How to improve the surface highlight effect of the prototype models?

Nowadays, the designers of the prototype industry are more and more strict in the requirements for board-like pieces, which will surely bring great challenge to the rapid prototyping industry and rapid prototyping companies.

For example, we usually are requested to make plastic prototypes with highlight effect, which requires master worker with rich experience in subsequent processing in a high level. In order to improve the quality of each prototype, the master in KAIAO, one of the top rapid prototyping companies in China will use at least three kinds of sandpaper to process on the prototype model surface until it’s polished. The more smooth it is polished, the higher the brightness. Of course, this is heavy workload.

After that, we generally do painting 3-4 times and then take the prototype into the dust-free workshop for UV processing. The highlight effect of prototype surface will be ideal then. However, it requires early inspection to see if the surface bonding is not good or the wall thickness is too thin or if UV processing causes rupture or deformation.

Prototyping Significance:

1. Verify the design, solve all kinds of fatal flaws in new products, avoid high risk.
2. Batch trial production, 2-3 days rapid prototyping, save up to several months time cost.
3. Sample exhibitors, quickly seize the market opportunities, instant access to a large number of orders and considerable cash.
To this end, the KAIAO has been studied over 19 years!

Zero risk commitment to protect your interests:

If you are not satisfied with the production of prototype highlight effect, accuracy of less than + 0.1mm, which can not meet your assembly requirements, or you feel the appearance of the sample prototype (fuel injection, silk screen, plating and other surface treatment), can not achieve 99% fidelity of the finished mold, you only need to return the prototype within 3 days after you receive it, we will immediately, unconditionally, free of charge for you to create a new set of prototype. Not only that, we undertake all the freight back and forth. Don’t hesitate to contact KAIAO for free here.

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.

Rapid Prototyping will be loved and trusted by many units and businesses

Rapid Prototyping, as an important economic system, is necessary to maintain a low-key innovative state and technology integration and it is the key to tensions in China’s manufacturing industry.

KAIAO, one of the top rapid prototyping companies in China, always follows the innovation rhythm in the background of SLA, SLS laser rapid prototyping model making, and is committed to the production of CNC rapid machining, low volume production of vacuum silicone molding. Due to KAIAO’s high-tech and high-end talents’ perfect cooperation, rapid prototyping in KAIAO is now loved and trusted by many units and enterprises. From the horizontal perspective, there are a lot of branches with wide service; from a vertical perspective, any branch is the chain from parts to complete products.

So, China’s equipment manufacturing industry is facing transformation and upgrading, you need to climb the slope of high-end global value chain as well as the core technology. Finally, as KAIAO elaborates, in order to stand out in the core and future of the equipment manufacturing, you will have to renovate in innovation and follow the times and meet people’s needs. And KAIAO prototype insisted on using market to promote the upgrading of equipment manufacturing industry, which is always believed to be the core and future of KAIAO.

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.

Problems in the Process of Silicone Rubber Mold Making

1. Reasonable choice and proper opening of the exhaust channel. The correct opening of the exhaust channel on the silicone mold has a great effect on ensuring the quality of the silicone prototypes. The exhaust position should be selected at the highest point of the mold cavity and ensure that the passage is open to prevent the exhaust passage from being clogged with the silicone so that the product can not be formed or has pores defect. As the elasticity of silica gel is very good, when gas needle pricks exhaust hole and we pull out the air needle, the airway will shrink to be smaller. In the product copy, you can insert fine-pored plastic pipe in the hole avoid silicone being clogged.

2. Correct control of the knife path. When cutting the mold with a knife, the walking path of the knife is a straight line with a knife nose, and curve with the tail, so the silicone rubber mold is irregular, so as to ensure accurate positioning of the upper and lower mold clamping molds and avoid dislocation caused by error.

3. Ensure that the material is mixed evenly. When the curing agent and silica gel mixed, due to the intense reaction, the mixture will produce a large number of bubbles and the volume becomes larger. At this moment, we should immediately enter air into the vacuum chamber, reduce the bubble, and continue to repeat this process to ensure that the curing agent and silica gel mix evenly.

For the rest three problems please visit:

http://www.kaiao-rprt.com/Technique/six-problems-in-silicone-rubber-molding.html

 

RIM, RRIM and SRIM

RIM molding is a kind of molding process that mixes two or more high-active raw materials under pressure, impinge-mix through the mixing head and inject into the mold to produce prototypes along with the chemical reaction. RIM molding can be used to produce fender, body panels and other large parts.

RRIM (enhanced reaction injection) molding is a kind of RIM moulding that adds fiber or filler in the liquid raw material components. RRIM moulding can produce good impact of the car shells, such as car door panels.

SRIM (structural reaction injection) molding produces roof frame, shell, trunk lid, bumper and so on. The glass fiber reinforced SRIM bumper produced by KAIAO for one of the top car manufacture in China, weighs about 3.45kg (7. 6lb) and it perfectly replaces the original steel bumper which is about 7kg. That is 50% of weight reduction and impact resistance also improves. KAIAO’s RRIM Polyurethane products have been used as a rear panel for the German Volkswagen.

Gas Assisted Injection Molding: the Basic Principles and Basic Processes

The basic principle of Air Mould is: put a certain amount of melt into the cavity, then the compressed air into the melt center, and then the melt will fill with cavity under the action of compressed air.

The basic process of GA IM mainly includes the following stages:

(1) Melt injection: the polymer melt is put into the mold cavity, the process is the same as with the traditional injection molding, the melt is generally filled with 60% to 97% of cavity, which varies by products;

(2) Gas injection: high-pressure nitrogen is put into the melt core, the melt flow is driven by high-pressure gas to move forward until the full cavity;

(3) Gas pressure: the workpiece is cooled while maintaining gas pressure; in the cooling process, the gas from the inside out pressure to ensure that the outer surface of the product close to the mold wall, and the internal supplement melt shrinkage caused by melt cooling through the secondary gas through;

(4) Gas pressure relief and recycling;

(5) Cavity open, remove the parts