Rapid tooling--a new approach to integrated product and process development

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Abstract
Rapid prototyping technologies -- especially stereolithography and plastic laser sintering -- did substantially contribute in reducing product development times. But models that are produced by rapid prototyping technologies do not meet the requirements of functional prototypes, as neither the serial material nor the serial production processes are used. This concerns injection molding and pressure die-casting prototypes. Therefore rapid tooling techniques are necessary. The main emphasis of this presentation is on the significance of rapid tooling for integrated product and process development. This is discussed using the example of evolution tooling (tools that grow with the development status). Furthermore, a survey is presented of the most important rapid tooling processes that employ rapid prototyping technologies. A distinction is made here between the process chains for rapid prototyping and conversion processes and the direct manufacture of tool components. The IWB User Center (Anwenderzentrum) in Augsburg, Germany is the first European user of the indirect metal laser sintering process. In order to communicate what has been learned from initial experience with this procedure, sample tools that have been realized are described.

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