Method for fabrication of molds and mold components

Abstract

The present invention relates to a method for rapid fabrication of molds and mold components. This method involves first the step of producing a digital CAD representation of the mold; using this digital representation to make a set of oversized core and cavity three dimensional models, patterns or replicas, by using solid modeling technologies; placing these models, patterns or replicas respectively into a mold base with die pockets to accept the patterns; powder injection molding fine metal powders around each version of the core and cavity of the part to produce a 'green' molded article having the negative or female impression or the original core and cavity patterns; debinding these 'green' articles to remove the binder; sintering the debound articles to produce the final tool steel or related alloy molds; and performing secondary operations to fit then into a master mold base as part of a complete molding tool. These molds or molding dies and mold components can be used as part of a rapid prototyping mold or as permanent mold that can be used produce parts made out of plastic, metal, ceramic or composite materials. The result will be a reduction both in time and cost as compared to the construction of a standard injection molding die using established methodologies of carbon electrode grinding, electric discharge machining (EDM) and other processes.