Design of Prototypes & Injection Mould Tooling for Manufacturing by Direct Metal Laser Sintering (DMLS) Technology

Generally, Prototypes & injection mould toolings are produced by conventional, Computer Numerical Control (CNC) machining & electrical discharge machining processes. Making moulds by these methods is slow and expensive for low batch quantities. Product complexity is increasing & product cycles are growing ever shorter Therefore Rapid Prototyping (RP) tooling fabrications should be considered for projects in which the reduction of time to market is important, for prototypes and short to medium volume production runs.

At least six different Rapid Prototyping technologies are commercially available in the market. Direct Metal Laser Sintering (DMLS) is one such Rapid Prototyping technology for producing prototypes & toolings for injection moulding & investment casting processes using metal powder (Bronze Nickel). EOSINT M250 machine from M/s EOS Gmbh-Germany is a direct metal laser-sintering machine.

Each manufacturing process has its advantages and limitations from the point of accuracy, shape, surface finish & cost. This paper deals with the brief description of EOSINT M250 RP machine, process, design rules for parts, accuracy surface finish & geometry of parts that are best suited for DMLS technology from the point of cost and time.