The KelTool™ method is a specialized technique for rapidly manufacturing molds, particularly suited for applications that do not require extremely high precision but demand durability and efficiency. This method excels in producing molds with a dimensional accuracy of ±0.04 mm within a size range of 250 mm. The technique is ideal for producing low-precision molds, making it a versatile choice for a variety of industrial applications.

Key Application Areas of the KelTool™ Method

The KelTool™ method is primarily used for rapid prototyping and low-precision mold production. It is most beneficial when manufacturing molds for large-scale production runs that require a balance between speed, cost, and mold durability. This method is commonly applied in industries where the molds do not need to meet the highest precision standards but still need to deliver reliable and functional products.

1. Mold Manufacturing for Prototyping and Testing The KelTool™ method is widely used to create prototypes and test molds, particularly in the automotive, electronics, and consumer goods industries. The rapid prototyping capabilities of this method allow designers and engineers to quickly move from concept to functional molds, facilitating the testing and evaluation of designs before committing to more expensive, high-precision molds.
2. Low-Precision Production Molds For products that do not require the highest precision, the KelTool™ method provides a cost-effective and efficient way to manufacture molds. This includes applications where ±0.04 mm tolerance is sufficient, such as in the production of components for the automotive and consumer product industries. The molds produced can withstand significant wear and are ideal for use in industries with moderate precision requirements.
3. Mass Production of Functional Parts Once the mold has been created using the KelTool™ method, it can be used for mass production of functional parts. These molds are particularly useful for injection molding, casting, and other manufacturing processes that involve large volumes of parts. As the method can produce molds with excellent durability and a longer service life (up to one million cycles), it is highly suitable for industries that require high-volume production with moderate precision tolerances.

Example Molds and Products Manufactured Using the KelTool™ Method

As seen in the diagram below (Figure 9-3), the KelTool™ method is capable of producing not only the mold cavity but also the entire assembly required for functional production. The molds produced through this technique can be used for the efficient manufacturing of a wide range of products.

Additionally, Figure 9-4 shows some examples of products produced using molds created through the KelTool™ method. These products highlight the versatility and efficiency of the process in producing functional, durable parts that meet the necessary requirements for various applications.

Conclusion: Why the KelTool™ Method is Ideal for Low-Precision Mold Production

The KelTool™ method offers an excellent solution for industries looking for rapid mold production with moderate precision requirements. With the ability to produce durable molds at a significantly reduced cost and time compared to traditional methods, it is well-suited for prototyping, low-precision molds, and large-scale production runs. The process’s unique combination of tungsten carbide and tool steel powders ensures that the final mold is durable, with a long service life, and able to withstand wear during production.

This makes the KelTool™ method a preferred choice for industries that require efficient and cost-effective mold production without sacrificing performance. The ability to rapidly produce functional molds while maintaining acceptable precision levels provides a competitive advantage for manufacturers in many fields.