SLS For Tooling Applications

Abstract

A system for sintering a tool within a laser sintering system includes a chamber enclosing a sinter material. The laser sintering system grows or sinters the tool from the sinter material in response to signals from a controller. The controller generates these signals as a function of a predetermined tool design. A heat sink is positioned within the chamber to cool features of the tool, thereby limiting warping of these features during sintering of the tool.

Description

FEDERAL RESEARCH STATEMENT [0001] [Federal Research Statement Paragraph] This invention was made with government support on contract N00019-01-C-0012. The Government has certain rights in this invention.BACKGROUND OF INVENTION [0002] The present invention relates generally to tooling systems and processes and is more specifically related to the fabrication of tools through selective laser sintering. [0003] Traditional fabrication methods for tools having areas of contour have included fiberglass lay-ups on numerically controlled machined master models or facility details. [0004] A manufacturing master model tool, or “master model”, is a three-dimensional representation of a part or assembly. The master model controls physical features and shapes during the manufacture or “build” of assembly tools, thereby ensuring that parts and assemblies created using the master model fit together. [0005] Traditional tool fabrication methods rely on a physical master model. These master models may...

AI Technical Summary

Benefits of technology

The present invention is a system and method for manufacturing tools using laser sintering technology. The system includes a chamber enclosing a sinter material and a heat sink to prevent warping of the tool during sintering. The method involves predetermining the position and orientation of the tool section to minimize warping, and then sintering the tool section within the chamber. The use of this technology can significantly reduce costs and cycle time, and the model remains the master definition of the tool, allowing for root cause analysis or detail replacement. The technical effects of the invention include reduced costs, improved efficiency, and flexibility in tool design.

Problems solved by technology

Master models are costly in that they require design, modeling and surfacing, programming, machine time, hand work, secondary fabrication operations, and inspection prior to use in tool fabrication.

In summary, although used for years, physical master models have inherent inefficiencies, including: they are costly and difficult to create, use, and maintain; there is a constant risk of damage or loss of the master model; and large master models are difficult and costly to store.

Selective Laser Sintering has, however, not been generally available for tool manufacture because of SLS part size limitations, lack if robustness of SLS objects, and inherent limitations in the SLS process.

The disadvantages associated with current tool manufacturing systems have made it apparent that a new and improved tooling system is needed.

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