This paper describes an algorithm based on accessibility-driven partitioning approach to automate the design of sacrificial multi-piece molds. Sacrificial multi-piece molds are used for producing geometrically complex gelcast ceramic parts. The algorithm presented in this paper analyzes the accessibility of the gross mold shape and partitions it using accessibility information. Each partitionin...

This report describes a CAD approach for automated ejectability analysis and parting surface generation for mold tool design. This design automation is incorporated into a Rapid Tool Manufacturing system which integrates stereolithography (SLA) and thermal spraying into a CAD/CAM environment for manufacturing tooling like injection molds. Design models are first evaluated for part ejectability ...

The design of injection molding systems for plastic parts relies heavily on experience and intuition. Recently, mold makers have been compelled to shorten lead times, reduce costs and improve process performance due to global competition. This paper presents a framework, based on a Multidisciplinary Design Optimization (MDO) methodology, which tackles the design of an injection mold by integrat...

Improved design process consists of four steps. These steps are prototype step, design step, analysis step and mold step, respectively. The error constitution of these steps is analyzed. Through the error analysis on both improved design process and reverse process, the total error of reverse improved design is essentially formed by reverse error, design error, analysis error and mold error. Fo...

Injection mold development lead time has been reduced presently by over 50% by employing rapid prototyping based tooling methods. Rapid tooling methods however, have certain limitations in terms of mold material, accuracy, surface finish, and mold life. The relevant process knowledge, especially for newer routes, is not very well established, resulting inconsistent or inappropriate rapid toolin...

Injection mold development lead time has been reduced presently by over 50% by employing rapid prototyping based tooling methods. Rapid tooling methods however, have certain limitations in terms of mold material, accuracy, surface finish, and mold life. The relevant process knowledge, especially for newer routes, is not very well established, resulting inconsistent or inappropriate rapid toolin...

Recent developments in Computer Aided Design (CAD) have drastically reduced overall design cycle time and cost. In this paper, wirePATH, a new method for rapid direct tooling, is presented. By using specialized interactive segmentation computer software and wire electrical discharge machining (wire EDM), wirePATH can reduce manufacturing time and cost for injection molds, casting patterns, and ...

Particularly for rapid tooling applications, delivering prototype parts with turn-around times of less than two weeks requires fast, proven mold design methods. We present a region-based approach to automated mold design that is suitable for simple two-piece molds (consisting of core and cavity), as well as molds with many additional moving sections. In our region-based approach, part faces are...

A thermomechanical study of the effects of mold topography on the solidification of Aluminum alloys at early times is provided. The various coupling mechanisms between the solid-shell and mold deformation and heat transfer at the mold/solid-shell interface during the early stages of Aluminum solidification on molds with uneven topographies are investigated. The air-gap nucleation time, the stre...

Casting metals and alloys makes most of the parts for vehicles. To shorten the time to market and get a satisfied quality new design approach have to be involved. New CAD based technologies are giving an opportunity to make molds faster and cheaper with a high quality than previously using classical methods. In this paper master mold design process including decision about materials is presente...