The RapidTool™ process, developed by DTM Corporation, utilizes Sinterstation 2500—a Selective Laser Sintering (SLS) system designed for efficient rapid prototyping and mold manufacturing. Initially, the materials used in this system were primarily thermoplastic materials such as PVC, PC, nylon, and wax powders. These materials were originally intended for creating shell molds used in casting processes. Over time, however, the range of materials suitable for the system has been expanded, providing greater flexibility and improving the overall process.

Materials Used in RapidTool™ Process

The range of materials compatible with the RapidTool™ technology now includes three main categories, each offering unique properties suited to specific applications:

1. Acrylic-Based Powders (TrueFormPM): This category includes acrylic-based powders like TrueFormPM, which provide high detail accuracy and are suitable for creating prototype molds that require intricate designs.
2. Synthetic Materials (Nylon and Glass Bead-Reinforced Nylon): These materials are a combination of nylon reinforced with glass beads, offering enhanced strength and durability. These materials are particularly useful for applications that require higher mechanical performance and robustness in the molds.
3. Polymer-Bound Low Carbon Steel Powders (e.g., Rapid Steel 2.0): Rapid Steel 2.0 is a powder material used in the RapidTool™ process consisting of low-carbon steel powder particles that are pre-bound with a polymer binder. This material is especially designed for creating mold cores that exhibit both the strength of steel and the precision of rapid prototyping.

Sinterstation 2500 Equipment

The Sinterstation 2500 system, an integral part of the RapidTool™ process, operates using the Selective Laser Sintering (SLS) technology. This advanced system utilizes a laser to sinter the material layer by layer, effectively bonding the particles together to form solid structures. The sintering process ensures that the molds created are not only durable but also capable of maintaining the precision required for high-quality production.

Conclusion

The RapidTool™ process offers a versatile and efficient solution for mold manufacturing, utilizing a wide range of materials to meet the diverse needs of different industries. With materials ranging from acrylic-based powders to nylon composites and low-carbon steel powders, the Sinterstation 2500 system facilitates rapid mold creation with excellent strength, precision, and durability. By expanding the available material options and combining them with the SLS technology, the RapidTool™ process significantly enhances the overall speed and quality of mold production, making it an invaluable tool for modern manufacturing.