MANUFACTURING METHODS FOR MANDRELS TO MAKE NICKEL VAPOR DEPOSITION TOOLING

THREE METHODS ARE PROPOSED FOR MAKING NET SHAPE HIGH TEMPERATURE MANDRELS TO FORM CHEMICALLY VAPOR DEPOSITED NICKEL SHELL TOOLING BASED ON SOLID FREEFORM FABRICATION (SFF) MODELS. THE THREE METHODS ARE DISTINGUISHED BY THE NUMBER OF GENERATIONS OR REPLICATIONS THE NICKEL SHELL WILL BE FROM THE SFF MODEL:3, 2, OR 1. THE 3 AND 2 GENERATION METHODS USE CHEMICALLY BONDED CERAMIC MATERIALS TO FORM THE MANDREL BECAUSE OF THEIR COMPATIBILITY WITH SFF MODELS COUPLED WITH PRECISION, QUICK AND EASY FORMABILITY, THERMAL STABILITY, AND THERMAL CONDUCTIVITY. THE SINGLE GENERATION METHOD REQUIRES THE DEVELOPMENT OF A HIGH TEMPERATURE SFF MODEL. A METHOD IS IDENTIFIED THAT COULD POTENTIALLY DO THIS. THE SHELLS FORMED FROM THESE MANDRELS WILL BE INCORPORATED INTO INJECTION MOLDS BY BACKING THEM WITH CBC AND MOUNTING THEM IN A STANDARD MOLD FRAME. THE MOLD WILL BE TESTED FOR PART PRECISION AND CYCLE TIME. THE ANTICIPATED APPLICATION OF THE TECHNOLOGY IS THE TOOLING INDUSTRY AND, SPECIFICALLY, THE MATCHED DIE MOLDING INDUSTRY. ENHANCED AUTOMATION OF COMPLEX MOLD PRODUCTION WOULD IMPROVE THE WORLDWIDE COMPETITIVENESS OF THE U.S. TOOL AND DIE INDUSTRY AND DRAMATICALLY REDUCE COSTS FOR ANY INDUSTRY THAT RELIES ON MOLDED PARTS, PARTICULARLY THOSE WITH PRODUCTION RUNS LESS THAN 25,000 PARTS.