Metal spray process

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For the production of a higher number of similar workpieces, the use of the metal spray process for the production of molds is beneficial. These forms are then z. B. used for injection molding or blowing plastic parts. The metal spray process is therefore only one element in the replication of the prototypes , which must be followed by the actual production of the small or medium series.

Procedure

At the beginning of the production of the mold, a release agent is applied to the master model and the mold parting plane is defined with the aid of a plate. With the help of a special spray gun, a thin layer of metal is then applied to the master models and the molding level. For this purpose, the required material is liquefied by heating in the spray gun. The thickness of the layer is selected depending on the load on the shape to be produced. It is about 2-4 mm. This shape is in a mold frame. The remaining cavity is filled with the help of a special material.

The filling material consists of a plastic or plaster mixture which, if necessary, can be used to improve the resilience of the manufactured tools. B. glass fibers or iron filings can be added. After the first half of the mold has been completed, the other required moldings are made. Cores and other elements can also be integrated to manufacture the parts. With the help of exciting post-processing, the shape in the surface can be improved and provided with additional elements (e.g. ejectors). The mold is then available as a tool for producing an average number of workpieces.

The tool created is now available for use in manufacturing the series parts with the aid of injection molding or blow molding.

Advantages and disadvantages

The production of molds with the help of the metal spray process and their use offers the following significant advantages:

  • larger tool life of the shapes produced
  • higher resilience of the shapes produced
  • greater variety of materials that can be processed in the mold

At the same time, the following disadvantages must be observed:

  • high material and time expenditure to manufacture the molds
  • fast wear on filigree form elements

application areas

One area of ​​application for the metal spray process is the production of small series and prototype series within the Rapid Product Development process chain .