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| What is 3D Keltool? |
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The 3D Keltool process typically starts with a CAD design of the core and cavity mold inserts, followed by the creation of the core and cavity patterns with stereolithography or some other RP process.
Once these core and cavity patterns have been finished to the desired surface, silicone rubber is cast against them to create molds into which a mixture of metal powder and binder is poured, packed and cured. The metal mixture consists of finely powdered A6 tool steel and even finer particles of tungsten carbide. At this point, the cast core and cavity inserts exist in a green state. These green inserts are fired in a hydrogen-reduction furnace to burn away the binder, sinter the metal particles and infiltrate copper into the inserts. This produces solid metal inserts that are approximately 70 percent steel and 30 percent copper with physical properties similar to that of P20 tool steel. The inserts are finish-machined, drilled for ejector pins and fitted into mold bases. The tools from this process show very good definition and surface finish. Lead-time is typically shorter than conventionally produced tooling. The primary disadvantage is size limitation. The maximum size of a mold insert is 150 x 215 x 100 mm (5.9 x 8.5 x 4 inches). The length in the z-direction can extend to 145 mm (5.75 inches) when the x and/or y dimensions are shorter. Some toolmakers have press fit two or more inserts side-by-side - in a mold base - to create larger tools.
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