The ExpressTool™ rapid molding process is a cutting-edge technology that incorporates the use of nickel-copper composite shells with conformal cooling channels to create highly efficient and durable molds. This process, developed in collaboration with Hasbro and LaserFare, has become a breakthrough in the field of mold manufacturing, offering numerous advantages over traditional mold-making methods. Below, we explore the key features of the ExpressTool™ process and its wide range of applications.

1. High Thermal Conductivity

One of the standout features of the ExpressTool™ rapid molding process is the high thermal conductivity of the nickel-copper composite shell. Compared to any type of traditional mold steel, the nickel-copper composite offers significantly better heat transfer properties. This allows the mold to cool faster, and it ensures a more uniform mold temperature distribution. The improved heat dissipation leads to better control over the molding process, contributing to faster production cycles and improved part quality.

2. Easy Integration of Conformal Cooling Channels

A major advantage of the ExpressTool™ process is its ability to integrate conformal cooling channels. These cooling channels can be designed to follow the contours of the molded part, ensuring that the mold temperature is more evenly distributed and that hotspots—areas where the mold tends to overheat—are minimized. By reducing the number of hotspots, the mold maintains a more uniform temperature profile, which in turn helps to reduce the stress induced during the injection molding process, leading to less warping and deformation of the final part.

The use of conformal cooling channels can also shorten the injection cycle time, improving overall efficiency and productivity in mold manufacturing.

3. Increased Injection Molding Productivity

The ExpressTool™ process can significantly increase the productivity of injection molding. When compared to traditional machined steel molds, molds produced using the nickel-copper composite shell and conformal cooling channels can increase injection molding productivity by an average of 33%. The faster cooling rates and more efficient heat management contribute to reduced cycle times, allowing manufacturers to produce more parts in less time.

4. High Precision of Electroformed Nickel Shell

The nickel shell in the ExpressTool™ process is produced using electroforming, a method that offers high precision. The electroforming process can replicate features as small as 0.1 micrometers, with minimal shrinkage during the molding process. This precision ensures that the final mold is almost an exact replica of the original prototype, providing accurate and reliable results in high-precision molding applications.

5. Shorter Manufacturing Cycle

Another significant benefit of the ExpressTool™ method is its reduced manufacturing cycle. The production time for molds using this technology is approximately one-third to one-half of the time it takes to produce traditional machined steel molds. This shorter production time not only speeds up the mold-making process but also reduces the overall time-to-market for products that require injection molding.

6. Excellent Corrosion Resistance

The electroformed nickel surface of molds created through the ExpressTool™ process is highly resistant to chemical corrosion. Unlike traditional mold steels, the nickel coating provides enhanced protection against corrosive substances, ensuring that the mold remains in excellent condition over extended use. This corrosion resistance is particularly valuable in industries where molds are exposed to harsh chemicals or high temperatures, extending the life of the mold and reducing maintenance costs.

7. Superior Surface Quality

The fine grain structure of the electroformed nickel shell results in a high-quality surface finish. This surface quality is essential for producing parts that require a smooth and flawless finish, such as plastic lenses. After polishing, the electroformed nickel surface can achieve excellent surface quality, making it ideal for high-precision molding applications that require aesthetic and functional surface properties.

8. Easy Mold Repair

Molds produced using the ExpressTool™ method are also easier to repair compared to traditional molds. If the surface of the mold becomes worn or damaged over time, it can be repaired using the electroforming process. This allows for cost-effective maintenance and extends the lifespan of the mold, making it a more sustainable option for long-term production runs.

9. No Size Limitations

Another significant advantage of the ExpressTool™ rapid molding process is that it is not constrained by size limitations. The process can be used to create molds of various sizes and complexities without the need for specialized equipment or complex techniques. This flexibility makes ExpressTool™ suitable for a wide range of molding applications, from small parts to large, intricate components.

Applications of the ExpressTool™ Rapid Molding Process

The ExpressTool™ method is well-suited for a variety of industrial applications, including:

• Injection molding of high-performance plastic parts
• Production of molds with complex geometries that require precise temperature control and uniform cooling
• Batch production of parts where speed and efficiency are critical
• High-precision molding applications, such as optical lenses and aesthetic components
• Mold repair and maintenance for long-term use in demanding environments

In conclusion, the ExpressTool™ rapid molding process offers a multitude of benefits that make it a superior choice over traditional mold-making techniques. From high thermal conductivity and easy integration of conformal cooling channels to shorter production cycles and improved mold life, this innovative process can significantly enhance the efficiency, quality, and cost-effectiveness of molding operations across various industries. With its high precision, corrosion resistance, and ease of repair, ExpressTool™ sets a new standard in rapid mold manufacturing.