The RapidTool™ process produces core molds composed of 60% steel (w(Steel)) and 40% copper (w(Cu)). The total shrinkage rate during the furnace process is between 2.5% and 3.5%, and the hardness can reach up to 27 HRC. The material’s mechanical properties surpass those of A17075, with a mold lifespan that can exceed 50,000 cycles.

Advantages of the RapidTool™ Process

1. Fast Production: One of the major advantages of the RapidTool™ process is its speed. The production of a mold core takes only about 5 to 15 working days, allowing for rapid mold creation and faster time-to-market for manufacturers.
2. Improved Cooling Efficiency: The 40% or 50% copper content in the mold core enhances the cooling performance of the mold, significantly reducing the cycle time. This is crucial in injection molding processes, where fast cooling times improve overall production efficiency and reduce costs.
3. Long Mold Lifespan: Molds created using the RapidTool™ technology have excellent durability and can endure over 50,000 production cycles, making them ideal for high-volume production runs.
4. Machinability: The mold cores produced via the RapidTool™ method can be easily processed using traditional machining tools, which is an essential feature for customizing or refining molds as needed during production.

Disadvantages of the RapidTool™ Process

Despite its numerous advantages, there are some drawbacks to the RapidTool™ process:

• Risk of Deformation During Copper Infiltration:
  During the copper infiltration process at 1120°C, high temperatures may lead to deformation of the mold core. While this is an inherent challenge of high-temperature sintering and infiltration, careful temperature control and process monitoring can mitigate this issue.

Conclusion

The RapidTool™ process offers a highly efficient and cost-effective solution for producing metal molds, particularly for injection molding applications. With its quick production time, excellent cooling efficiency, long mold lifespan, and compatibility with traditional machining, RapidTool™ technology is a valuable tool for manufacturers aiming to optimize their production processes. However, managing temperature fluctuations during copper infiltration is crucial to avoid potential mold deformation. Despite this, its benefits make it a standout option for rapid prototyping and low to medium-volume production.