FDM Advanced Applications

The sand casting process is relatively simple, and the production of the sand molds and cast metal parts is relatively quick. However, the fabrication of the patterns to produce the sand molds can be time consuming. The application of FDM to the sand casting process reduces the pattern development time to expedite the receipt of prototype or production sand cast parts.

Sand Casting Using FDM Additive Fabrication Technology

Silicon / RTV Molding with Stratasys Soluble Support Cores

FDM offers an easy, fast and cost-effective alternative to machining or molding complex soluble cores. Instead of building the core in an FDM model material, it is made from WaterWorks support material. After casting, the WaterWorks core dissolves and leaves the desired cavity in the urethane part.

Extrusion Blow Molding

When FDM is used to construct blow molds, the lead time for prototype parts is reduced from weeks to less than five days. In addition, the cost for prototype tooling is significantly less than that of machined tools. In most cases, the FDM tooling will cost one-third to one-half that of a prototype aluminum tool. The FDM process is unique in its use of thermoplastics, and it is this feature that provides the benefits of rapid tooling for blow molding. Polycarbonate, which is one of the FDM materials, can withstand both the temperature and pressure of blow molding. With no wear or deformation, an FDM tool can produce hundreds, even thousands, of molded parts in common materials like HPDE, LDPE, PET, PVC, polycarbonate, polystyrene, and polyethylene.

Molded Fiber / Paper Pulp Molds

Replacing the design, machining and screening processes of traditional mold building, FDM automates and accelerates mold production. What would take two to four weeks to complete can be finished in two to four days with only a few hours of labor (see figure 3). Using FDM, fiber molders can produce customer samples quickly and affordably. Since FDM fiber forming molds have produced in excess of 30,000 pieces, the prototype tool transitions to a bridge-to-production solution for high-volume or the production tool for low-volume, custom jobs.

Spin Casting using FDM parts

FDM addresses the need for fast delivery of durable and accurate patterns. By replacing the machined metal patterns, the entire spin casting process, including pattern making, can be completed in as little as one day.

Inserting Metal in FDM Parts

It is well known that an FDM build can be paused and a metal object inserted into the part. The challenge is to properly adhere the FDM plastic to the metal after the build is resumed. There are mechanical and chemical differences between metal and FDM plastic that prevent adhesion.

Electroplating Using FDM Masters

With simple finishing techniques, FDM parts are ready for electroplating with alloys that include chromium, nickel, copper, silver and gold. Combining the material properties of FDM with those of a metal coating, the part has strength, durability and heat resistance that is ideal for functional applications.

Wood Grain and Leather Wrapping Finishing Technique

Wood Grain treatment, applied to an FDM part, uses a water-based dip coating to give models a wide variety of decorative finishes, ranging from wood grains to high-tech geometric patterns. These finishes are visually appealing, wear-resistant, and are similar to finishes currently used in many automotive interiors.

Leather Wrapping adds a very high-end, luxurious look and feel to models. There are approximately 250 leather colors and grains are available and padding can also be added under the leather for a softer feel.

RP & Mfg. Equipment