Community Research and Development Information Service - CORDIS

Rapid, High Accuracy Casting Technology for Long Life Injection Moulding

The industrial objective of this project was to develop a method of generating designs for tool Inserts from component cad data and to use this 3d cad data to drive rp processes which Will produce the inserts, which can be used in the investment casting process. Such a process would enable injection moulding tool inserts to be produced more rapidly, And at less expense than the current route.
During the project, work has demonstrated that this is a valid route for the production of low to Medium complexity tools for injection, resin transfer, polyurethane and thermoplastic rubber Processing. The feasibility of direct investment casting tools has been proven and repeatable Casting techniques have been developed. In addition, case study components have been Moulded for use by the consortium in marketing the technology.
It has been found that the accuracy of the casting process reduces as the casting size Increases. Large flat plates with a high aspect ratio in the z to x axis and similar, large x, y, Lengths tend to warp excessively. As a result cavity and core inserts have been designed Rather than whole tool plates, as the latter are generally too large to remain flat. The as-cast Condition is serviceable although rather brittle and very hard. However a solution treatment and tempering curve has been produced for the a2 tool steel that produces a predictable hardness And more consistent microstructure.


Record Number: 22591 / Last updated on: 1999-06-02
Information source:
Collaboration sought: Information exchange/Training
Stage of development: Other
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