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Rapid Tooling
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Rapid Tooling

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What is Rapid Tooling
These are primarily used to create multiple prototypes. Rapid prototyping techniques are not economical when more than one prototype needs to built for the same component. In these cases different rapid tooling techniques have been developed to manufacture 25-30 prototypes, few hundred to a few thousand prototypes and prototypes in excess of 50000
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Marco Polo India Private Limited

Phase 2, Noida, Uttar Pradesh
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What is Rapid Tooling

These are primarily used to create multiple prototypes. Rapid prototyping techniques are not economical when more than one prototype needs to built for the same component. In these cases different rapid tooling techniques have been developed to manufacture 25-30 prototypes, few hundred to a few thousand prototypes and prototypes in excess of 50000 pieces.

Techniques
 
Vaccum Casting
In this process moulds are made of silicon rubber material. The process involves making of the master pattern using any available rapid prototyping techniques. This pattern is then finished to the quality in which final parts are required. It is then suspended in an enclosed box and liquid silicone rubber is poured all around it. This sets with time and becomes a solid rubbery mass with the pattern inside. Now the mould is cut along its parting line and the pattern is removed from within.

This results in formation of the core and cavity. Because the material is flexible, undercut release is not a problem.

These moulds are good enough for 25-30 pieces in materials replicating properties of thermoplastics.
 
Epoxy Tooling
This process is similar to that of vacuum casting. The only difference being that instead if silicone rubber, the material used is aluminum filled epoxy.
 
Once the mould is made from this material, it can be put on a moulding machine and components can be moulded in actual material of choice. The mould life normally is upto 200 pieces.

Hybrid Tooling
Tooling is also made of different materials such as ZAMAG which is an aluminum and zinc alloy. Using this material in the above process we can get components moulded in actual material. The mould life is close to 1200 pieces.

Depending on the complexity, size and requirement of the component, the right process has to be chosen to arrive at a solution. Many times, one particular process may not be the solution, and several processes together with conventional tooling methods are used to arrive at a workable solution. This is called Hybrid Tooling. We also make tools by conventional tooling methods using aluminum material for short run production.

Direct Metal Laser Sintering
In this process, the material used is an alloy of Nickel and Bronze. A Laser beam is used to sinter the material selectively to manufacture the core and cavity inserts directly from CAD data. This technique is a layer additive technique for making the inserts. These inserts after they have been made on the machine can be directly put on the moulding machine after desired level of polishing.

The basic principle is that initially the CAD data is sliced by the RP software and then each slice layer is sintered by the laser beam being deflected in X-Y direction. After one layer is complete, the build platform moves down by a pre determined layer thickness (usually 0.1mm) and then the second layer is cured over it. This way the entire prototype is built up by subsequent joining of layers.

The advantage of this process is that it eliminates the use of conventional CNC machining, EDM and wire cut work from the process of manufacturing complicated inserts. This process saves time drastically over conventional techniques
 
The tool life obtained from this technique is comfortably 50000 pieces in ABS material. All other thermoplastics can be processed with the tool life depending on the abrasive nature of the plastics material.

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Rapid Tooling

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About us

Legal Status of FirmPrivate Limited Company
Nature of BusinessManufacturer
IndiaMART Member SinceFeb 2014
Marco Polo was started in 1992 as a trading and export company. In 1999 Marco Polo diversified into Product Development activities and now offers range of technology services for fabrication of all types of metal/ plastic components.
Presently the company has a factory of 7,500 Sq ft. The company has purchased another plot for further expansion / diversification.
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