The 3D Keltool process typically starts with a CAD design of the core and cavity mold inserts, followed by the creation of the core and cavity patterns with stereolithography or some other RP process.
Once these core and cavity patterns have been finished to the desired surface, silicone rubber is cast against them to create molds into which a mixture of metal powder and binder is poured, packed and cured. The metal mixture consists of finely powdered A6 tool steel and even finer particles of tungsten carbide. At this point, the cast core and cavity inserts exist in a green state. These green inserts are fired in a hydrogen-reduction furnace to burn away the binder, sinter the metal particles and infiltrate copper into the inserts. This produces solid metal inserts that are approximately 70 percent steel and 30 percent copper with physical properties similar to that of P20 tool steel. The inserts are finish-machined, drilled for ejector pins and fitted into mold bases.
The tools from this process show very good definition and surface finish. Lead-time is typically shorter than conventionally produced tooling. The primary disadvantage is size limitation. The maximum size of a mold insert is 150 x 215 x 100 mm (5.9 x 8.5 x 4 inches). The length in the z-direction can extend to 145 mm (5.75 inches) when the x and/or y dimensions are shorter. Some toolmakers have press fit two or more inserts side-by-side – in a mold base – to create larger tools.
3D Keltool is the only commercially proven rapid moldmaking solution that produces prototype, bridge, and production inserts in a prototype timeframe. It is ideal for rapidly creating complex part geometries and feature-dense inserts for injection molding and die casting applications.
Hundreds of 3D Keltool users have made thousands of inserts that have produced millions of molded parts. 3D Systems is now licensing this fast tooling technology to moldmakers wanting to have an advanced time-compression tooling solution in-house.
Production Tooling in a Prototype Timeframe – a commercially proven moldmaking solution from 3D Systems
Faster mold completion, Lower moldmaking costs, Improve competitiveness, A tool in the moldmaker’s toolbox
Typical 3D Keltool Applications:
Meet critical delivery deadlines, Produce molds requiring a lot of EDM electrode work, Make complex mold geometry & feature-dense designs, Decreased cycle times and improved mold cooling, An alternative to CNC on difficult to machine details, Produce multiple cavity molds quickly, When only a pattern or no 3D CAD data is available
Key benefits include:
Increase moldmaker productivity by 2x, Lower moldmaking costs 25-40%, Accelerate mold deliveries, Increase production capacity, Reduce cycle time by 30% or more 1,000,000+ shots possible, Proven with a wide variety of materials, Ideal for injection molding and die casting, Be Competitive in the Global Marketplace
Time-to-market and increased competition are two of the issues challenging moldmakers’ ability to succeed. As product lifecycles become shorter, customers are pushing to maximize product life and revenue by demanding faster deliveries. In addition, the growing global marketplace is enabling countries with lower labor rates to successfully compete in what used to be isolated markets. The resulting increase in competition is placing pressure on moldmakers to become more competitive.
Moldmakers are now strengthening their competitive advantage by using 3D Keltool. Accelerating mold deliveries enables them to hold onto current business while going after new opportunities. 3D Keltool gives moldmakers the ability to increase capacity and make molds faster and at lower cost. 3D Keltool helps companies compete in the global marketplace and gives them a tool they need to survive.
3D Keltool Delivers
Molded Parts in Production Materials, Engineering plastics & die casting metals, Accuracy to within +/- 0.2%, Rockwell Hardness (Rc) of up to 50, Excellent process for multicavity, Fast Molds at a Lower Cost
3D Keltool inserts in 8 calendar days
Reduce costs 25-40% compared with CNC tools for complex geometries, CAD model to molded parts in as little as 3 weeks, Ideal for multicavity mold applications, Outstanding Mold Properties
Up to millions of injection molded parts from a single set of 3D Keltool inserts, 500,000 to one-million-plus parts per mold for glass-filled resins is possible, Molding cycle times accelerated by 30% due to improved thermal conductivity of copper loaded inserts, 3D Keltool is a moldmaking tool that complements CNC and EDM machining
3D Keltool is the only commercially proven rapid moldmaking solution that produces prototype
3D Keltool is the only commercially proven rapid moldmaking solution that produces prototype, bridge, and production inserts in a prototype timeframe. It is ideal for rapidly creating complex part geometries and feature-dense inserts for injection molding and die casting applications. Hundreds of 3D Keltool users have made thousands of inserts that have produced millions of molded parts. 3D Systems is now licensing this fast tooling technology to moldmakers wanting to have an advanced time-compression tooling solution in-house. Production Tooling in a Prototype Timeframe ,Faster mold completion
Lower moldmaking costs, Improve competitiveness, A tool in the moldmaker’s toolbox
3D Keltool is a powder metal process used to make injection-mold inserts and other durable tooling from master patterns. Keltool was originally developed by 3M in 1976 and was sold and further developed by Keltool Inc. In 1996, 3D Systems purchased the technology from Keltool Inc. and renamed it 3D Keltool. 3D Systems continued to develop and improve the process. It is proprietary, so many of the details of 3D Keltool are not publicly known.
3D Keltool process is based on work performed from about 1972 until 1986 at Minnesota Mining and Manufacturing Corpora- tion, now simply referred to as 3M Corp. The process, originally referred to as ‘Tartan Tooling’ by 3M, is fundamentally a powder metallurgy approach.
3D Keltool is the only commercially proven rapid moldmaking solution that produces prototype
3D Keltool is the only commercially proven rapid moldmaking solution that produces prototype, bridge, and production inserts in a prototype timeframe. It is ideal for rapidly creating complex part geometries and feature-dense inserts for injection molding and die casting applications. Hundreds of 3D Keltool users have made thousands of inserts that have produced millions of molded parts. 3D Systems is now licensing this fast tooling technology to moldmakers wanting to have an advanced time-compression tooling solution in-house. Production Tooling in a Prototype Timeframe – a commercially proven moldmaking solution from 3D Systems
Faster mold completion
Lower moldmaking costs
Improve competitiveness
A tool in the moldmaker’s toolbox
The main keys in the 3D Keltool process are: solid CAD, design tool, precision in the piece on SL, finish of the piece, 3D Keltool, assembling the mould, injection moulding. Until recently some of these elements were difficult to achieve, but both the own 3D, and users of Stereolithography, laboratories services, clients, manufacturers of molds and transformer by injection are working to make this a reality.
The Keltool process is an advanced process of producing long-life softtooling quickly and economically for prototype and production runs from one tohundreds to even millions of plastic injection molded parts.The word “Keltool” refers to the proprietary powder metal sintering process,which involves infiltrating a fused metal part with copper alloy. This alloy fills inthe voids in the otherwise porous material, producing a surface with the finish andhardness necessary for an injection mold.
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