Rapid tooling using plasma spraying and rapid prototyping

Abstract

In the race to fabricate a product to market with increases in speed, cost and quality, the drive to economically decrease tooling lead times becomes more important. Rapid tooling (RT) fabricated at Tsinghua University uses a metal plasma spraying process and rapid prototyping (RP) to form a metal tool. The process uses plasma spraying as the heat pool to melt metal powder and then deposit molten metal on to the substrate made by RP. It provides a quick, accurate, simple and relatively cost effective route for producing metal parts or tools, especially for large tools. The process and key technologies are analysed and described in detail. Applications illustrate that the total costs and lead times for new products can be reduced.