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Rapid recyclable tooling manufactured from sodium silicate bound particulate materials

Objective



Industrial Need It is widely recognised that one of the most critical factors determining the competitiveness of manufacturing industries is an ability to reduce time-to-market. At the same time there is increasing pressure on industry to employ production processes which have a little or no effect on the environment. The proposed project aims at developing a relatively cheap and rapid method of manufacturing tooling which can be "dissolved" in water after use and the material recycled into new tooling. Project Objectives The overall objectives of the project are to : (1) reduce time to market by developing a new method for rapidly manufacturing production tools using particulate materials (metal, ceramic powders) bound with high strength, water soluble, inorganic binders. It is anticipated that the project will lead to the development of a method enabling the lead times for blow and rubber moulding tools to be reduced to 1 week and reduced to 2-4 weeks for plastic injection and die casting tools. (2) reducing the impact on the environment by developing methods to efficiently break down the binder so that powder used to manufacture the tools can be partially or wholly recovered and recycled. (3) to demonstrate the technology developed under production conditions in a number of industries including blow moulding, rubber moulding, superplastic forming, plastic injection moulding and die casting. This will also include a demonstration of recycling tools by breaking down binders, recoating powders and producing new tools from the recoated powders. The basic process on which the new toolmaking method is based was originally developed by one of the partners for the manufacture of environmentally friendly (and recyclable) sand moulds/cores for the foundry industry. It was only recently realised that the process could potentially be developed into a method for the manufacture of production tools (e.g. blow forming tools, plastic injection moulding tools). Patent protection for the basic process has already been sought. Estimated Timescale (After Completion Of RTD) For Process Development and Time To Market. It is estimated that, following completion of the project, the time required to further process development and time to market will be as follows: (a) 8-10 months for blow and rubber moulding tools (b) 12-15 months for superplastic, plastic injection moulding and die casting tools Relationship Of The Proposed Project With The Brite Euram 111 Workprogramme The project objectives correspond to key objectives outlined in Area 1 of the Brite-Euram III Workprogramme - specifically the sections entitled 1.1.7M. (Section 1.1.), and 1.2.2M. (Section 1.2.).

Funding Scheme

CSC - Cost-sharing contracts

Coordinator

DANISH TECHNOLOGICAL INSTITUTE
Address
Gregersensvej
2630 Taastrup
Denmark

Participants (10)

Adema & Touw BV
Netherlands
Address
16,Kapittelweg 16
4837 HG Breda
Aluminium - en Bronsgieterij Klava B.V.
Netherlands
Address
7,Surinamestraat 7
2612 EA Delft
HOLEC Laagspanning B.V.
Netherlands
Address
61,Tuidorpstraat 61
7550 AA Hengelo
NEDERLANDSE ORGANISATIE VOOR TOEGEPAST NATUURWETENSCHAPPELIJK ONDERZOEK TNO*
Netherlands
Address
6,Bevesierweg, Harssens (Mml)
1780 AM Den Helder
Rosti A/S
Denmark
Address
32,Brydehusvej 32
2750 Ballerup
Stellana AB
Sweden
Address

695 22 Laxaa
Superform Aluminium
United Kingdom
Address
Cosgrove Close
WR3 8UA Worcester
Svirco
Denmark
Address
8,Industrivej 8
5750 Ringe
TREVIRA NECKELMAN A/S
Denmark
Address
Kejlstrupvej 84-88
8600 Silkeborg
Trevira GmbH & Co. KG
Germany
Address
Max-fischer-strasse 11
86399 Bobingen