The KelTool™ M method is an advanced rapid manufacturing technique designed to create high-performance metal molds. This process utilizes a combination of rapid prototyping, silicone rubber soft molds, and a unique sintering process to produce strong and durable metal molds. The method is highly effective in creating steel molds for various industrial applications, providing precision, efficiency, and cost savings compared to traditional mold manufacturing techniques.

Basic Principles of the KelTool™ M Method

The KelTool™ M method combines several advanced manufacturing technologies to produce metal molds with high precision and strength. The process begins with the design of the concept prototype using 3D CAD software. This prototype includes both the cavity and core of the mold. The design is then saved as an STL file and transferred to a rapid prototyping system for the creation of the original prototype. The key steps in the process include:

1. Concept Prototype Design:
   The initial design of the mold, including both the cavity and core, is created using 3D CAD software. This digital design is then saved in STL file format, which is compatible with rapid prototyping systems.
2. Rapid Prototyping:
   The STL file is sent to a rapid prototyping system where the original prototype is manufactured. This prototype serves as the basis for creating the silicone rubber soft mold.
3. Silicone Rubber Soft Mold Creation:
   The original prototype is used to create a silicone rubber soft mold. This soft mold captures the details of the original prototype and is an essential step for the subsequent manufacturing of the metal mold.
4. Casting the Dual-Phase Metal Powder Mixture:
   In a vacuum, pressure-free environment, a mixture of two different metal powders of varying particle sizes is prepared. These powders are combined with an organic resin binder in precise proportions and poured into the silicone rubber soft mold. This mixture undergoes curing to form a “green body,” a semi-solid metal mold precursor.
5. Sintering Process:
   The “green body” is then placed in a sintering furnace under a hydrogen atmosphere. During the initial low-temperature stage of the sintering process, the organic binder is burned off and removed by the flowing hydrogen gas. As the temperature increases, the pure metal powders sinter together to form a skeleton-like structure with uniform porosity.
6. Copper Infiltration for Density:
   To further densify the structure, a second metal, typically copper, is infiltrated into the porous skeleton during the final sintering stage. This process transforms the skeleton into a fully dense metal mold, which is now capable of withstanding the demands of high-performance molding applications.
7. Final Metal Mold:
   The final result of the KelTool™ M method is a high-strength, high-precision metal steel hard mold. The mold typically consists of 70% dual-phase mixed metal powder and 30% copper by mass. The hardness of the mold can vary depending on the composition of the dual-phase mixed metal powder used in the process.

Properties of Molds Made Using the KelTool™ M Method

The steel hard molds produced using the KelTool™ M method offer several key advantages:

• High Hardness: The hardness of the molds can reach up to 46-50 HRC, depending on the composition of the dual-phase mixed metal powders used, such as A6 mold steel powder and tungsten carbide powder. This makes the molds suitable for high-performance industrial applications.
• Durability and Strength: The combination of sintered metal and copper infiltration results in a mold that is both strong and durable. These molds can withstand high temperatures and pressures, making them ideal for injection molding and other industrial processes.
• Precision: The sintering process, combined with the use of high-quality metal powders and copper infiltration, ensures that the molds maintain high dimensional accuracy and excellent surface finish, which is critical for producing high-quality molded parts.

Advantages of Using the KelTool™ M Method for Metal Mold Manufacturing

1. Faster Production Time: The KelTool™ M method significantly shortens the production time of metal molds compared to traditional manufacturing techniques. This is especially beneficial for industries where time-to-market is crucial.
2. Cost-Effectiveness: The process offers substantial cost savings by reducing the need for extensive machining and traditional mold-making methods. The use of rapid prototyping and the efficient sintering process makes it an affordable solution for small to medium-scale production runs.
3. High-Quality Molds for Various Applications: The KelTool™ M method can be used to produce molds for a wide range of applications, including those that require high strength and precision, such as injection molding of PP, PE, ABS, POM, and PA66 (with up to 50% glass fiber filler). This versatility makes the method suitable for many industries.
4. Customization and Design Flexibility: The method provides the flexibility to create molds with complex geometries that would be difficult or impossible to achieve using traditional methods. This allows for more innovative and efficient designs.

Conclusion

The KelTool™ M method offers a groundbreaking approach to metal mold manufacturing, combining the speed and flexibility of rapid prototyping with the strength and precision of sintered metal molds. This process enables manufacturers to produce high-performance molds quickly and cost-effectively, making it an excellent solution for industries that require precision molds for high-quality production runs. By leveraging advanced technologies such as rapid prototyping, sintering, and copper infiltration, the KelTool™ M method represents a significant advancement in the field of metal mold manufacturing.