Manufacture of RP tools with high quality surface finish using high temperature epoxy resin and electroless nickel plating

Abstract

Rapid tooling is gaining increasing attention in the manufacturing sector, especially for the development of new products, owing to its distinctive characteristics. Rapid prototyping techniques can be used in this prospective manufacturing area to produce tooling either directly or indirectly. Although powder metal based rapid prototyping systems are considered most effective for rapid tooling, the requirements for injection moulding are not yet fully attained. In the present study, rapid tooling produced by direct laser sintering of metal powder has been investigated with the aim of improving its quality for industrial acceptance. High temperature epoxy resin was used to fill the pores to improve compressive strength, and electroless nickel plating was employed to enhance hardness, conductivity, ductility, lubricity, wear, and abrasion resistance without affecting dimensional accuracy. Results demonstrate that these techniques possess significant potential for rapid tool productions.