| RADICAL | This project is closed |
| Rapid Laminated Die Casting Tooling for the Automotive Industry |
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Context There is significant pressure to reduce the cost and time to develop new products. Improved "agility" in responding to customer requirements, environmental concerns and new legislation is a key success factor in an increasingly competitive global market. The manufacture of tooling for both prototypes and final production is a major burden in terms of cost and lead-time. Previous work on rapid tooling has concentrated on tolls for plastic forming and sheet metal pressing. Die casting has been neglected because of the extreme technical challenges of finding construction methods that will resist the harsh operating conditions including elevated temperatures and severe thermal shock. Aims The aim is to reduce the cost of prototype tools by 50%, of production tooling by 40%, and reduce the time to produce a tool by 50%. It is also expected that the production rate for die cast components can be doubled through the incorporation of cooling channels into the tool. Method The process will be similar to the Laminated Object Manufacturing rapid prototyping technique, but using steel sheets rather than resin bonded paper. Benefits The new technique will be directly relevant to the operations of the partners. The automotive industry will gain from lower cost, flexible tooling that can be delivered within a shorter lead time. Die casting companies will be able to supply castings in shorter lead times and at lower cost. Tooling companies will become more competitive through faster response to their customers. Participants De Monfort University Land Rover Perkins TRW Kay Presteigne, TransTec Cast Products, Sulzer Metco Webster-Knights |
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