Case Study

Project: Aluminum Cap

Project Goals: To produce a viable method for the rapid production of prototype diecast tools and parts. Specific project goals:

• Time Frame: To produce prototype diecast parts in 6 - 8 weeks or less.
• Quantity: Produce between 50 and 200 prototype parts.
• Method Validation: Determine the validity of rapid tooling processes for the production of diecast zink and aluminum parts.
• Part Characteristics: Produce prototype parts with the characteristics of production diecast parts.

Process Chosen: DTM RapidSteel v2.0

Overview: Bastech, Inc. proposed a joint development project to produce a prototype diecast tool and parts for a nationally known pneumatic products manufacturer. The initial intent of this effort is to first produce diecast parts in zink and, after validation, move to aluminum. It is the eventual goal of Bastech to use the fundamental information gained during this project, to offer a commercially viable prototype diecasting method to the industry.

Process: The customer supplied Bastech, Inc. with a fully drafted CAD model with preferred parting line information. Bastech used this information to design the cavity and core geometry. The inserts were then created on a DTM-2500 Sinter Station using the new RapidSteel v2.0 material. The build took 35 hours and produced fragile "green" part. The green parts were then sent through two 22-hour furnace cycles. During the first cycle the original binder that holds the part together initially is burned out and the sintering of the metal particle occurs. During the second, the tools are infiltrated with bronze to fill the void left by the burn out of the binder. This creates a 100% dense part. The parts will then be finished through traditional means.

Bastech has partnered with Fort Recovery Industries (fri.com), a full service production die casting facility located in Fort Recovery, Ohio for the shooting of the dies. It is our intent to begin producing zink parts and after validation of the process, moving on to aluminum. Our current plan is to complete our initial run of parts around mid November and have comprehensive data by December.

We would like to make clear that this project is experimental in nature and no results can be guaranteed. Please visit our web site often for updates!