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MoldFusion is the name of a three-dimensional rapid tooling technology dubbed "metal printing" by Extrude Hones (Irwin, PA) ProMetal division, and its partner, mold component and tooling supplier D-M-E Co. (Madison Heights, MI). The process uses stereolithography techniques to build molds layer by layer from 3-D CAD models out of powdered tool steel and a binder matrix. The result is molds with near-net-shape cavities and mold faces for minimal machining and finishing and "impossible" internal features and geometries, the companies say.
Invented at MIT, MoldFusion is not a replacement for conventional tooling, but rather a rapid tooling solution for applications that are not practical using conventional metalworking, such as molds featuring conformal cooling water lines and dynamic thermal-cycling features. Not only is the time for building the mold shortened, the resulting mold generates parts 20-35% faster through the...