MCP Rapid Tooling

RAPID TOOLING

RAPID REALISATION

RAPID MANUFACTURING

RAPID PROTOTYPING

MCP RAPID TOOLING TECHNOLOGIES

Content

MCP Realizer IISLM-SLM Technology 4

MCP Vacuum Casting System 6

MCP Nylon Vacuum Casting 7

MCP Metal Part Casting Process 8

MCP Injection Moulding Machines 10

MCP EP Tooling Resins 11

MCP Low Melting Print Alloys 12

About MCP 15

Customer Training and Support 15

MCP Group Addresses 16

Page 4

A new world-class generative processdeveloped for direct product realisation with Selective Laser Melting.

Applications include sheet metalpress tools, pressure die castingtools, injection moulds and finitemetal. Even high quality metal partssuch as components for medicalimplants can be produced to exactdetails.

The advantages of the MCP Realizer II SLM:

• Builds high quality parts andtooling inserts from almost any type of metal: Stainless steel (toolsteel), titanium, cobalt-chromeand various nonferrous-metals.

• Special designed HQ-Powders.

• Dense and homogeneous build up of components and tool cavities up to 100% depending on requirements.

• Fast and low cost because no postprocessing required such as likeheat treatment or infiltration.

• Same day process, produce thecomponent (insert, press or mould parts) literally withinhours. Fully automatic buildingprocess – parts overnight.

• Produces tools and inserts withinternal undercuts and channelsfor conformal cooling.

• High resolution, dimensional accuracy, no distortion.

• Quick building process – 7.000 mm3

dense steel per hour on average.

How the MCP Realizer II SLM

(Selective Laser Melting) works

3D CAD Data

STL File

SLM Examples

Individually generated medical implants, dentalbridges and crowns. Material: Cobalt chromeand stainless steel (316 L) with material proper-ties better and more durable than castings.

Light weight construction, hollow core, wallthickness 2 mm, with inner supports. Material:Titanium (TiAI6V4) and stainless steel (316 L).These applications and prospects are seen in the areas of medical implants, aircraft andautomative industry.

Injection mould insert in dense stainless steel(316 L). The built-in conformal cooling channelsreduce cycle times.

Tooling made from stainless steel (316 L) forheavy gauge sheet metal formings. 3000 partswith 3 mm thickness without visible wear.

SLM (Selective Laser Melting) is a registered Trademark of F & S GmbH.

A full package turnkey system, first introducedin 1987 for producing exact and complicatedprototype components in vacuum plastic, nylonand wax materials. A package system generallyincludes a combination of vacuum castingmachines and ovens of the size required, tooling materials – usually silicone rubber – anda range of over 30 MCP Vacuum Plastics (com-parable in performance to thermoplastics), and,important accessories. A full course of training,in-house at the customer’s premises, worldwideis always included.

With this process, multi segment molds can bemade overnight to be cut open the next dayready for casting the first prototypes on thevacuum casting equipment. Using the MCPVacuum Casting Technique 30 to 50 color mat-ched functional prototypes can be producedwithin two to three days from any type ofmodel. MCP Vacuum casting is now becomingthe state-of-the-art technology for achieving technical prototypesfor exhibition and functional testing and molddesign checks. On average, users can expect tosave 97% in time and cost compared to conven-tional steel tooling.

Widest range of materialsMCP is the largest supplier with the most com-prehensive and best performing range of vacu-um casting materials and silicone rubber too-ling materials worldwide.

Worldwide, the most widely used system forprototype part manufacture –The MCP Vacuum Casting System

Multi colour prototypes.Produced with the MCPVacuum Casting System. Completely Different Applications for MCP Vacuum Casting Machines

VarioPressure Casting.Parts from highly vis-cous materials(Silicone).

Wax castings formetal investment cast-ing.

Fusible CoreTechnology: internallyundercut plastic cast-ings.

EP Tooling Resin processed on MCPVacuum Machines.

MCP Nylon Vacuum Casting

A completely new Rapid Prototyping, RapidManufacturing Process for prototype and productionparts in Nylon PA-6. This new technology has all theadvantages of the MCP standard Vacuum CastingProcess.

• Quick, accurate, multi-segment siliconemold making within 12 hours

• Use any type of model

• Demold in only 6 minutes after casting

• Extremely thick and thin walled parts

• MCP PA 2000, PA 1000 and PA 700 have all theproperties of injection molded nylon polymers (see comparative data below)

• MCP Nylon Castings are air, gas and water tight

• Can be welded and glued

• Chemically resistant

• Can replace metal components

Some applications: automotive inlet manifolds, engine compartment parts, lamp housings.

MCP Vacuum Cast Parts can also be used for clips,living hinges, containers, 2 part inlet manifold shells,air filter housings, radiator water tanks and gears.

The MCP 4/04 NylonModule VersionMachine. Easy to usecontrols to guaranteebest casting results.

Load the silicone mold.Standard silicone moldtechnology is used forthis process.

Close the doors and letthe PLC controller takeover.

Unit PA 12NYLONPA 2000 PP

NYLONPA 1000 ZYTEL®

NYLONPA 700 PE HD PE LD

TestISO / DIN

Flexural Modulas Mpa -- 1950 950 862 750 -- -- 178 --

Tensile Modulas Mpa1000 -

20001800 1300 850 900 650

700 -

1400200 - 500 R 527

Tensile Strength Mpa 52 - 60 60 15 - 37 42 41 32 18 -35 18 - 35 R 527

Heat Deflection

Temp. (HDT)

1,8 Mpa

°C 42 - 80 105 45 51 71 49 50 50 - 35 75 (A)

Heat Deflection

Temp. (HDT)

0,45 Mpa

°C -- 195 120 131 140+ 76 50 50 - 35 75 (B)

Comparative data: Injection moulded DuPontTM Zytel® ST801 Polyimide 66, conditioned. Data after conditioning

1

2

3

MCP NYLON PA 2000MCP NYLON PA 1000MCP NYLON PA 7003

2

1

Rapid Metal prototyping and manufacturing – The finest in Investment Casting TechnologyThe MCP Metal Part Casting Process

Pressure Die Casting QualityGuaranteed!

The MCP Metal Part Casting Processhas been designed specifically tomeet the increasing demand forquick, economical metal castings forprototypes, low and medium runsof several hundred parts.A new and complete package pro-cess for producing quick metal pro-totypes and mold inserts in as littleas one day in materials such aszinc, aluminium, bronze, brass andcopper when using “burn out”models in wax, polystyrene (SLS) orQuick Cast or, three days whenusing other types of model. Fromwhich molds for casting waxes needto be made.

To apply the new process, wax cast-ings or meltable models are requi-red, which are encapsulated in cera-mic and heated and melted out toleave a cavity which is filled withmetal either under vacuum, pressu-re or gravity using the MCP MetalPart Casting Equipment.

The automated Metal Part CastingEquipment is suitable for a cleanlaboratory type environment notusually associated with a foundryapplications.

Further important advantages of the process:

Use Any Rapid Prototyping ModelStart the process with any type ofmaster model such as SLA,QuickCast, Objet, ThermoJet,Viper, LOM, SLS, FDM etc. and inany complexity.

Combined Technologies

Low Cost ToolingUtilise the MCP Silicone ToolingMethod to produce quick, lowcost, multi segment moulds forwax part production, impossiblewith standard, traditional toolingmethods.Produce Precision Wax ModelsUse the well established methodof master model duplication, theMCP Vacuum Casting Process, toproduce thin walled, undercutwax models using silicone tooling.User Friendly, CleanThe automated Metal Part CastingEquipment, can be used in a cleanlaboratory type environment notusually associated with a foundryapplications. No heat radiation – No dirt – No fumes.

1

2

3

4

5

6

Set up the wax models adding the gate & some risers.Place the casting flask over the wax models.Mix and cast ceramic under vacuum to encapsul-ate the wax models in the flask.Place in the oven.Remove the flask from the oven and place into the casting unit and close.The PLC touch screen controller will operate all important parameters of the cast-ing process. Melting takes between 15 and 20 minutes depending on the type andamount of metals. The casting operation is performed automatically in just a fewseconds giving perfect results. No heat radiation, no dirt, no fumes.The metal part can be removed from the ceramic mold within 30 to 60 minutesafter casting.

6

5

4

3

2

1

Metal Part Casting Examples

Machine type Casting volume of metal Flask size

MPA 300 3,0 litres (8 kg Aluminium) Ø 350 x 500 mm

MPA 1000 10,0 litres (28 kg Aluminium) Ø 550 x 700 mm

MPA 1500R 15,0 litres

Some data (extract) on Metal Part Casting Units

3 days to complex metal parts- left, the model and the

multi-segment silicone mold- the highly accurate wax cast-

ing through MCP VacuumCasting

- right, the resulting castingthrough MCP Metal PartCasting in die casting quality

One day from the model tothe metal casting.SLS Polystyrene “burn out”model and the resulting MetalPart Casting in aluminium.

Left: The Rapid PrototypingModel.Center: The wax model produ-ced with the MCP VacuumCasting Technology.Right: The resulting complexaluminium component madewith the MCP Metal PartCasting Process.

The Rapid Prototyping Model (RP).

The wax model produced with theMCP Vacuum Casting Technology.

The resulting complex aluminiumcomponent, an automotive gearboxduct plate with more than 80measuring points, made with theMCP Metal Part Casting Process. 380 parts already produced forprototypes and pre-series requirements.

3

2

1

1 2 3

Product design and low series production –The MCP Injection Moulding Machinesfor prototypes and short run plastic parts

The quick and economic way ofmaking plastic components „inhouse“

MCP semi-automatic machines arecapable of a long or a shortproduction runs and are particularysuitable for insert moulding. Themachines have a power lock and adwell timer, enabling a pre-set rampressure to develop a single, timedinjection stroke at the push of abutton. Alternatively, MCP machinesprovide the option of manual ope-ration, a particulary useful featurefor setting up moulds. The mould isreadily accessible to the operatormaking mould changes andmodifications quick and convenient.

Specification: MCP 100 KSA Injection Molder

Locking pressure 20 t

Standard diameter* 35 mm

Injection pressure 410 bar

Shot weight 100 g

Heating capacity 1.8 kW @ 220V/110V

Plasticising capacity 7 kg/h

Electric supply 2 kW @ 220V/110V 50 or 60 cycles

Air supply Approx 8 bar

Maximum tool size** 150 x 150 x 250 mmH x W x D

Machine size 1280 x 760 x 400 mmH x W x D

Machine weight 260 kg

* Optional injection units are available** By removing the end stop, molds longer

than 250 mm can be used

Fields of Application• Production machine for proto-

type and small batch producti-on from 10 to 1000 parts

• Production machine for insertmoulding

• Laboratory machine for testingplastics and moulds

• Machine for schools and trai-ning establishments

• Injection moulding of waxmodels for investment casting

Advantages of the MCPMachines• Low cost• Robust design• Simple Installation• No servicing• Low space requirement• Simple low cost moulds• Easy mould access• Quick and easy mould and

material change• Relative to injection capacity

MCP Machines are the mostcompact and easy to use on themarket

Further Advantages of MCP-Injection Moulding Machines• Moulds almost any thermopla-stic materials• Quick material changes use low

cost „bridge tooling“ systemssuch as metal spray moulds,aluminium or EP 310

• Quick installation – easy to use• Moulds set-up within minutes• Permanent access to mould –

manual demoulding savescostly ejector systems

• High shot capacity – low investment

Fix casting frame and cooling pipes. Cast EP tooling resin.

Page 11

Quality injection tools in just a few days – MCP EP Tooling Resins

The path to product success

Shortened product cycles require new andbetter methods for realising productiontooling. Injection molding is in-ternationally the most used plastics pro-cessing method but conventional toolingfor this process is expensive and time con-suming to produce. New methods ofRapid Tooling such as EP tooling resinsshow that it can be achieved quicker andat a lower cost. Decisive is a materialwhich is easy to use and which will produ-ce tooling to fulfil all the requirements ofinjection molding. Further, the materialneeds to have similar stability to alumini-um with a high surface quality. With EPtooling resins, MCP-HEK has developed amaterial which fulfils all the requirementscompletely. Molds pro-duced in EP 250 show an extremely highglass transition temperature and compres-sive strength. Shrinkage is negligible atapproximately + 0.02 percent.Despite the high aluminium filler contentof 80 percent, EP tooling resin demonstra-te ex-cellent casting properties with high surfa-ce finish reproduction from any type ofmodel.

Chemical resistivity is above average andthe high quality dense surface can bepolished to a mirror like finish if required.For mold changes and alterations, EP too-ling resin molds can be reworked easilywithout losing mold stability andstrength. EP tooling resin tooling resinmakes possible the manufacture of quick,economically acceptable injection moldsand quality parts.

Day OneUse models in any materials:wood, plaster, leather, silicone,resin or any type of rapidprototyping model.Fit metal inserts if required.

Degas.

Processing EP ToolingResin

Remove the casting frame.

Heat cure the mold in the oven.

Degas again.

Completed injection tool.

Day Three

Cast EP tooling resin.

Day TwoFix upper castingframe.

Prototype sheet metal forming tooling usingMCP Low Melting Print Alloys

In as little as 2 days

Sheet metal forming tooling produ-ced with MCP 137 Low meltingpoint alloy is used by manyEuropean automotive manufactu-rers, such as BMW and DaimlerChrysler. These automakers use thisprocess prototype runs of 100 – 200pressings. This technology offers amultitude of tool making optionsfor the user:

Easy to use, clean process

The most straight forward procedu-re is to use an existing sheet metalcomponent (with the requiredmodifications), suspend this in acasting frame and cast the alloy toproduce the top and bottom toolsimultaneously. Generally, the stan-dard method of tool manufacture isto produce a model of either oneor other side of the componentrequired. The Low melt alloy is castagainst this model to produce thefirst half of the tool. Demolded themodel after cooling and lay up thecasting with pattern maker´s sheetwax in the required thickness ofsheet metal required, for example0.8 mm and cast low melt alloyagainst the wax sheet. Within amatter of hours after casting, thetool can be on the press to produceprototypes and small runs in mate-rials up to 3 – 4 mm. The processoffers options of integrating steelinserts and die plates for extendingtool life up to 2 – 3000 parts andcasting tools with blank holders fordeep drawing applications.

System Specification:MCP 137 Low melting point alloyand melting equipment are thebasic requirements to producetooling. Melting tanks aresupplied in sizes ranging from150 kg (approx 330 lbs) meltingcapacity and up to 60 metric tonsalloy capacity for producingautomotive floor pan press tools.The alloy is completely re-usable.

The finished component,manufactured in a MCP SheetMetal Forming Die.

Coat with wax sheet in the thickness of the sheetmetal to be used and cast theMCP Alloy to produce the bot-tom die.

Assembled punch and blank-holder.

Punch and blankholderfinished.

To produce the punch, fill thecasting pattern with MCPAlloy using a pre-preparedsheet metal retainer frame.

Prepare a model of any mate-rial ie: wood, tooling board,styrofoam or SLA (Stereolitho-graphy)

Other Applications of MCP Low Melting Print Alloys

Make the Impossible: five cylinder inlet manifold in 35% glass filled nylon.Left: The metal core in MCP Low Melt Alloy. Center: The metal core, overmol-ded in plastic. Right: The finished component, after core melt out, internallyundercut, impossible to produce with conventional tooling methods.

A transparent, internally undercut, one piece MCP Vacuum Casting in SG 95.

Workholding of optical lenses (lens blocking). Worldwirde the standard technology for holding optical lenses in glass or plastic during grinding operations.

Tube and profile bending. Allows wrinkle free bending of the thinest of wallthickness. Also for producing “T“ pieces and complicated profiles. Use alloysfrom 70°C – 124°C melting temperature.

Workholding of turbines blades. Worldwide the standard technology forholding aircraft and steam turbine blades using alloys from 70C – 137°Cmelting temperature.

Melting tanksfor casting andre-meltingMCP alloys.Melting tanksare availablein many size.

About MCP

From MCP's earliest days as a Bismuth specialist a global approach todistribution and marketing has been called for. An international presence isimportant too for raw material purchasing and trade in scrap and residues.Our local companies and agents have become a key factor in ourdetermination to provide un-equalled customer service.

An important task for MCP is to develop further our markets in EasternEurope and in Asia.

Demonstration Centres are important too as a method of ensuring effectivecommunication with customers. Trained application engineers, operating inpurpose-built centres, are best able to deal with client queries and advise onthe latest techniques and materials.

Customer liaison and co-operative ventures are vital but we also haveextensive dialogue with Universities and Institutes so that our concepts arealways "out in front". Increasingly efficient use of scarce resources will alwaysrequire a radical approach.

The Group's Central Laboratories have recently been expanded and re-equipped. They are now housed in a state-of-art facility on theWellingborough site and provide an unrivalled service to all MCP companies.Quality Control must surely be at the heart of every successful business: MCP’slaboratory for optimum control is a fine example of this philosophy.

The MCP Group Internet site is a popular point of reference for thoseinterested in Minor Metals, Low Melting Point Alloys, Bismuth Chemicals,Rapid Prototyping or other MCP products and services. All are welcome toseek technical or commercial information and can do so quickly andeconomically round the clock using the e-mail links provided. MCP Internetand e-mail addresses are listed in full at the end of the broshure.

MCP’s Worldwide Success

Comprehensive, individual customer training has been a major contributor tothe tremendous worldwide success of MCP Vacuum Casting processes. A further important factor is the total package supply concept which includesmachines and equipment, tooling materials, casting materials, accessoriestraining and service – all from MCP. One supplier: complete responsibility forcustomer satisfaction!

Complete equipment • materials • customer trainingbased on DIN ISO 9001 – worldwide

Rapid Tooling and RapidManufacturing Seminars.

Practical interactive training.

Individual training.

Service and training manuals,technical Videos and CD-ROMs.

EURO TECH CENTER, Kaarst • Germany

MCP’s 2.000 m2 purpose built manufactur-ing and demonstration facility in Stone,Staffordshire • England

Complete Package Worldwide

Equipment - Materials - Training

MCP RAPID TOOLING PROCESS TECHNOLOGY FROM A-ZOver a period of 45 years the MCP Group of companies has grown to become a leading innovatorwith a worldwide reputation for supplying, installing and training in advanced mould technologies.

MCP Tooling Technologies Ltd.Whitebridge Way · Whitebridge Ind. ParkStone · Staffordshire · ST15 8LQ · EnglandTel. +44 (0) 1785 81 56 51Fax +44 (0) 1785 81 21 15E-Mail: [email protected]

MCP France S.A.70, Rue Amelot · F-75011 Paris · France Tel. +33 (0) 1 47 00 88 09Fax +33 (0) 1 47 00 37 95E-Mail: [email protected]

MCP Italia Srl.Via Lomellina 12/b rossoI-200 90 Buccinasco (MI) · ItalyTel. +39 (0) 02 488 52 11Fax +39 (0) 02 488 43 400E-Mail: [email protected]

MCP Iberia.S.A.C/Ingenero Fernandez Casado, 5E-288 20 Coslada (Madrid) · EspanaTel. +34 (0) 91 - 669 41 82/669 4236Fax +34 (0) 91 - 669 40 24E-Mail: [email protected]

MCP Technology73, Y.Kolas str.220113, Minsk · Republic of BelarusTel. +375 17 2625590, 2625612Fax +375 17 2620441E-Mail: [email protected]

MCP Systems Inc.511 Commerce DriveFairfield, Connecticut 06432 · USATel. +1 (0) 203 367 7761 Fax +1 (0) 203 368 4787E-Mail: [email protected]

HEK GmbHKaninchenborn 24-28D-23560 Lübeck · GermanyTel. +49 (0) 451 5 30 04-0Fax +49 (0) 451 5 30 04-50E-Mail: [email protected]

EURO TECH CENTERKaarst/DüsseldorfNovesiastrasse 31D-41564 Kaarst · GermanyTel. +49 (0) 2131 5 10 56-0Fax +49 (0) 2131 5 10 56-32 E-Mail: [email protected]

http://www.mcp-group.de

MCP equipment and materials are exclusively distributed throughout Eastern Europe, Middle East, India, Pakistan, Far East, Australasia, S. America and S. Africa.20

0480

05 -

© 1

0.20

04 H

EK G

mb

H,

Ger

man

y. W

e re

serv

e th

e ri

gh

t to

alt

er t

ech

nic

al s

pec

ific

atio

ns

wit

ho

ut

pri

or

no

tice

. A

ll p

rod

uct

s ar

e (r

egis

trat

ed)

trad

emar

ks.

Än

der

un

gen

un

d I

rrtü

mer

vo

rbeh

alte

n.

Alle

gen

ann

ten

Pro

du

kte

sin

d (

ein

get

rag

ene)

War

enze

ich

en.

Cre

atio

n:

ww

w.s

tah

r.de

RAPID TOOLING

RAPID REALISATION

RAPID MANUFACTURING

RAPID PROTOTYPING

MCP RAPID TOOLING TECHNOLOGIES

MCP Rapid Tooling

Documents

Transcript of MCP Rapid Tooling