Rapid Prototyping and Tooling Technology to Assist the Development of Low-Cost Dies

This case study aims toward the importance of the application of rapid prototyping and tooling technology in die design and manufacturing. Many conventional machining processes of die manufacturing, including computer numeric control (CNC) machining and electric discharge machining (EDM), are used by the local manufacturers of die, but these processes are time-consuming and expensive. There is a need to explore opportunities to reduce die manufacturing costs. This paper aims to assist the development of low-cost dies through the application of rapid prototyping and tooling technology. For this purpose, solid works software was used to design the die of a 4-hole Lego Block. 3D printing was incorporated in the existing capability of investment casting process for die manufacturing. A proper gating system design consideration was taken into account to ensure the accurate flow of casting material for achieving fine surface finish. From the results, it has been observed that gating system design with four ingates gives the optimum value of surface finish (~3.4156μm). The proposed rapid prototyping and tooling technology makes the practitioners (tool makers) capable of making dies with complex shapes, superior surface finishes, and dimensional accuracy in less or no time.