5. 3D Keltool mould
Keltool is currently considered to be the most promising method for the rapid manufacture of metal molds. It first uses the RP master model to produce a silica mold with higher precision, and then injects fine powdered A6 tool steel (or stainless steel) into the silica gel mold, and a mixture of finer tungsten carbide particles (note that the size of the powder particles is controlled). A very important factor in the final quality of the mold). An epoxy resin binder is then added to the mixture to form a green powder in the silica gel mold.
After the mold is opened, the green member is heated in the furnace to volatilize the binder, and at the same time, the metal powder mixture is sintered. At this time, there is still 30% of the voids in the mold, so the final copper infiltration is required, and finally it is available. For mass production, up to a million pieces of hard mold. Its dimensional accuracy is ±0.04mm per 250mm error. The downside is that the largest mold size that can be made by this method is currently only 127mm. Generally, this method can complete the mold cavity or core production in more than ten days, saving 25% to 40% of the cost compared with the traditional CNC machine tool processing.