Rapid prototyping technologies can either be a "dry" or a "wet" process. Most machines create prototype models by solidifying some sort of loose powder, liquid, or semi-liquid material. A machine may be able to cut through adhesive-coated sheets of prototype fabrication material. The dry powdered materials can either be some sort of polymer, powdered metal, or wax. Some machines may even be able to use starch as the building material for forming the prototype model. In a preferred embodiment, the method for rapid tooling manufacturing the second die half is formed by first the step of building an SFF model of a part to be molded. Then, there is the step of inserting the model into the first die half. Next, there is the step of spraying metal onto the model in the first die half to form a second metal substrate. Then there is the step of separating the second metal substrate from the model and the first die half to form the second die half. One such activity is the manufacture of toolinging (i.e., design, prototype, and fabrication) such as dies required for the high-volume production methods that generate most of our manufactured products. toolinging manufacture is typically an expensive and time-consuming process. The reasons lie not only in the fabrication costs and time constraints imposed by conventional machining methods, but also in the organizational framework. Products often make several complete cycles through design,
rapid prototyping, and fabrication before reaching production. Thus, new product development or product modification implies a series of iterative changes for both product manufacturers and toolingmakers. For all these reasons, a rapid and smooth transition from product concept to production remains a challenge. In a preferred embodiment, the method for rapid tooling manufacturing of the second die half is formed by first the step of building an SFF model of a part to be molded. Then, there is the step of inserting the model into the first die half. Next, there is the step of spraying metal onto the model in the first die half to form a second metal substrate. Then there is the step of separating the second metal substrate from the model and the first die half to form the second die half. Rapid Prototyping is also referred to as solid free-form manufacturing, computer-automated manufacturing, and layered manufacturing. RP is used to create a visual model. In addition, RP models can be used for functional testing, as when an airfoil shape is put into a wind tunnel. RP models can be used to create male models for tooling, such as silicone rubber molds and investment castings. In some cases, the RP part can be the final part, but typically the RP material is not strong enough or the RP part is not dimensionally accurate enough. When the RP material is suitable, highly convoluted shapes (including parts nested within parts) can be produced.
