A first approach to choose between HSM, EDM and DMLS processes in hybrid rapid tooling

Abstract

Purpose To propose a method to manufacture a hybrid rapid tool (a multi component tool). Design/methodology/approach The part is decomposed into multi component prototype instead of a part made from a single piece. First, this method is based on a topological analysis of the tool. Features are regrouped starting from the numerical definition of the die. Second, the manufacturing possibilities of the high speed milling (HSM), direct metal laser sintering (DMLS) and electro discharge machining (EDM) process are analyzed. Finally this information is synthesized to obtain solutions. This method is validated by industrial example. Findings A method is proposed to choose the best manufacturing process in order to optimize the manufacture of a “hybrid rapid tooling” between three processes: HSM, DMLS and EDM. So, it is possible to obtain the different components of the hybrid rapid tooling according to the envisaged process. Research limitations/implications The final goal is to propose a software assistant used in association with CAD system during the design of hybrid rapid tooling. An important work concerning the features recognition must be implemented. The assembly of the different parts of the hybrid rapid tooling must be considered and optimized. Practical implications This method allows the selection of the best process among EDM, HSM and DMLS technologies form manufacturing tools. Originality/value The analysis of manufacturing hybrid rapid tooling has not been studied yet.