Product category:
Rapid Prototyping
News Release from: Moog FCS | Subject: LaserForm A6 steel
Edited by the Engineeringtalk Editorial
Team on 28 October 2003
Production-ready steel for rapid
prototyping
LaserForm A6 steel is a new material for the 3D Systems SLS (selective laser sintering) system.
LaserForm A6 steel is a new material for the 3D Systems SLS (selective laser sintering) system The LaserForm A6 steel product is the latest addition to the family of metals for use with the SLS system for rapid and low-cost manufacture of plastic injection moulding tools, complex metal parts, prototype parts and other applications such as die casting tools and thermoforming tools
This article was originally published on Engineeringtalk on 20 Jun 2008 at 8.00am (UK)
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"With the introduction of LaserForm A6 steel, we are confident that we have achieved the development of a true production-ready steel product for our laser sintering system solution", says Chuck Hull, Chief Technology Officer for 3D Systems.
"The LaserForm A6 steel product was designed to meet the needs of the highly competitive tooling market for injection moulding of plastic parts.
This industry requires a technology solution that enables higher productivity while drastically reducing costs", says Hull.
"In order to successfully compete with conventional CNC and EDM in this market, the on demand manufacturing process (rapid tooling), must not only be faster, but must also substantially improve throughput of injection moulding equipment while meeting rigorous requirements for accuracy, surface finish, detail and durability.
Our new LaserForm A6 steel product offers excellent attributes for toolmaking and metal part production.
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When processed through our SLS system the LaserForm A6 steel has a production tooling hardness of Rockwell c10-20 and can be heat-treated up to HRc39.
Just like traditional metals, 3D Systems' LaserForm A6 steel product can be machined, EDM processed, polished, etched, welded, textured and more".
Hull continues: "LaserForm A6 steel product represents a new class of steel developed for our SLS system solution.
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This new product combined with a new process enables rapid layer fabrication of high performance production injection moulding tools and inserts, as well as durable, high strength steel parts for short run production.
This results in finished tooling with up to 50% faster injection moulding cycle times over conventional steel tooling, made possible by higher thermal conductivity and conformal cooling".
"Several technical advancements were required to achieve this material breakthrough, including optimal use of tungsten carbide for hardness and wear resistance, a new process for consistent part accuracy and a new binder system with outstanding green strength that enables the fabrication of fine detail, highly complex geometry, as well as the conformal cooling channels.
In addition to the advancements in material we are introducing a new high purity proprietary infiltrant for improved part surface finish straight out of the process and a completely new scanning technology for consistent run-to-run system performance, mechanical properties and accuracy of parts and tools".
Abe Reichental, Chief Executive Officer and President of 3D Systems says: "The development of the LaserForm A6 steel product is a significant achievement which enables the tooling industry to design, develop and manufacture tools in a fraction of the time and cost required with more traditional methods.
We are excited about our ability to achieve tooling industry customer requirements at our initial customer installations and view tooling and parts manufacturing as an exciting key market for our expanding rapid prototyping and on demand manufacturing system solutions".
The LaserForm A6 steel product has undergone rigorous use in the USA, including testing at Microplastics, St Charles, Illinois.
Microplastics serves the automotive, computer, appliance, telecommunications, medical and electronics industries, making it an ideal beta site for the LaserForm A6 steel product.
The facility houses a full-service tool room with advanced CNC and EDM capabilities.
Jim Spaniol, National Sales Manager for Microplastics says: "In answering our customers' requirements for faster program development at reduced cost, Microplastics has invested in the SLS system and the LaserForm A6 steel product, allowing us to participate in the earliest stages of our customers' product development cycle by providing both direct functional Polyamide plastic parts with our DuraForm material and rapid prototype tooling with our LaserForm A6 steel.
"By working with the Microplastics team, we can assure our customers that their insert moulded project will be developed with reduced cost in less time while providing team continuity from conception through production.
With the development of the LaserForm A6 steel product we are able to dramatically cut lead times and reduce tooling costs.
We now have the ability to compete with some of the global tooling challenges that we are faced with", continues Spaniol.
The new LaserForm A6 steel product and the SLS system is ideal for designers, parts manufacturers and toolmakers to increase manufacturing efficiency and productivity by offering rapid, cost-effective low-volume manufacturing of end-use metal parts, and near net shape tools for injection moulding and die casting.
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