Tool formed from a 3D printed tool holder

Abstract

A tool formed from a 3D-printed scaffold, comprising: a 3D-printed scaffold, a hardened casting material within the scaffold, and a forming surface defined by the scaffold. A method of forming a tool, comprising: 3D-printing a tool scaffold, wherein the scaffold defines a void volume and a forming surface; filling the void volume with a casting material; and hardening the casting material.

Description

[0001] Cross-reference to related applications

[0002] This application claims the benefit of U.S. Provisional Application 63 / 036,707, filed June 9, 2020, and its teachings are incorporated herein by reference. Technical Field

[0003] This disclosure relates to tools formed from 3D printed tool holders, and more particularly to casting tools formed from material extrusion 3D printed tool holders and processes for forming casting tools from material extrusion 3D printed tool holders. Background Technology

[0004] Tools are used to form parts from polymers or metals in processes such as injection molding, blow molding, compression molding, extrusion molding, vacuum forming, hydroforming, and casting. Tools typically include forming surfaces, such as cavities that serve as the base of the part or raised surfaces that serve as the front of the part. Tools are usually machined from a metal frame or made of wood. Tools can be simple or complex, depending on the process in which they are used. For example, in injection molding, a tool may require an ejection system, sprue bushings, cooling lines, a moving core, or other features. Increasing complexity increases costs, as does the materials and time required to manufacture the tool. The cost of each iteration of the tool used to form the part can be prohibitively expensive during the part development cycle and the production of prototype tools and parts, and the time required to adjust the tool can extend the part development cycle.

[0005] To address tool development and product cycle time challenges, additive manufacturing is sometimes used to form tools. In this process, tools are formed from polymer materials printed using methods such as high-speed extrusion, fused deposition modeling, laser sintering, stereolithography, material jetting, and others. However, in some applications, these tools may not be mechanically, thermally, or chemically robust enough to meet the molding cycle requirements for producing a sufficient number of parts for testing. Furthermore, additive manufacturing raw materials are relatively expensive, and depending on the tool's size and density, it may still take several days to form. In some cases, tools formed through additive manufacturing are not waterproof under pressure and may require additional treatment to seal cooling channels and the formed surfaces.

[0006] While current tooling techniques have achieved their intended purpose, new and improved tooling methods and tools made by such methods are still needed for molding parts from formable materials. Summary of the Invention

[0007] According to various aspects, this disclosure relates to a method for forming a tool. The method includes 3D printing a tool holder, wherein the holder defines a void volume and a forming surface. The method also includes filling the void volume with a casting material and hardening the casting material.

[0008] In the aforementioned aspects, the method further includes treating the tool holder before filling the void volume with casting material. In some aspects, treating the tool holder includes machining tool holders. Additional or alternative aspects include applying a release agent to the tool holder.

[0009] In any of the above aspects, the method further includes applying a magnetic field or electrostatic field to the tool holder when filling the void volume with casting material.

[0010] In any of the above aspects, the method further includes vibrating the tool holder after filling the void volume with casting material.

[0011] In any of the above aspects, a casting method is selected from the group of casting methods consisting of vibration casting, vacuum casting, pressure casting and centrifugal casting, and a casting material is used to fill the void volume.

[0012] In any of the foregoing aspects, hardening the casting material includes chemically reacting the casting material. In some aspects, the casting material is concrete, and chemically reacting the casting material includes hydration. In some aspects, the casting material includes thermosetting materials, and chemically reacting the casting material includes cross-linking the casting material. In some aspects, chemically reacting the casting material includes sulfidation of the casting material.

[0013] In any of the above aspects, the method further includes removing the tool holder from the casting material after hardening.

[0014] In any of the above aspects, the support further defines the cooling line, and the method further includes introducing a cooling or heating fluid or gas into the cooling line while the casting material is hardening.

[0015] In any of the above aspects, the support further defines the cooling line, and the method also includes sealing the cooling line.

[0016] In any of the above aspects, the method also includes sealing the molded surface.

[0017] In any of the foregoing aspects, the method includes generating computer numerical control (CNC) code from CAD files, wherein the CNC code is used for 3D printing tool holders. In some aspects, the method further includes merging multiple CAD files to generate CNC code.

[0018] According to various aspects, this disclosure relates to tools formed from 3D-printed scaffolds. The tool includes a 3D-printed scaffold, a cast material hardened within the scaffold, and a shaped surface defined by the scaffold. In some aspects, the tool is formed according to the foregoing aspects of a method for forming a tool.

[0019] In any of the above aspects, the tool also includes auxiliary features defined by a 3D-printed support, wherein the auxiliary features include cooling lines.

[0020] In any of the above aspects, the 3D printing tool holder includes multiple baffles. Attached Figure Description

[0021] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of this disclosure in any way.

[0022] Figure 1 A flowchart is shown illustrating a method for forming a casting tool using a 3D-printed tool holder according to an exemplary embodiment of the present disclosure;

[0023] Figure 2A A tool according to an exemplary embodiment is shown, in particular half of the tool base, which includes a shaped surface provided as a cavity in the tool base;

[0024] Figure 2B It shows Figure 2A The cross-section;

[0025] Figure 3A A tool holder for forming the tool shown in FIG2 is illustrated according to an exemplary embodiment;

[0026] Figure 3B It shows Figure 3A The cross-section;

[0027] Figure 3C It shows Figure 3A A three-dimensional digital representation of the tool holder;

[0028] Figure 4 A cross-section of a printing tool holder according to an exemplary embodiment is shown, such as the cross-section of FIG3;

[0029] Figure 5 A casting tool including a tool holder comprising casting material is shown according to an exemplary embodiment; and

[0030] Figure 6 A casting tool including a tool holder containing casting material is shown according to another exemplary embodiment. Detailed Implementation

[0031] The following description is merely exemplary in nature and is not intended to limit this disclosure, application, or use. This disclosure relates to casting tools formed from material extrusion 3D printed supports and processes for forming tools from material extrusion 3D printed supports. Tools may include clamps, jigs, gauges, molds, dies, cutting equipment, and models. Tools are used to form parts from formable materials such as polymers or metals in processes such as injection molding, blow molding, compression molding, extrusion molding, vacuum forming, hydroforming, and casting. Tools typically include forming surfaces, such as cavities as the substrate of a part or raised surfaces as the front of a part. Typically, the process involves forming a tool support using material extrusion, in some aspects using 3D printing, and filling the tool support to cast the tool. In alternative aspects, the casting tool is finished using at least one of the following processes: support removal, machining, coating, electroplating, and polishing. The casting tool can then be used to form parts from materials such as polymers or metals through molding processes including injection molding, blow molding, compression molding, rotational molding, composite lamination, extrusion molding, vacuum forming, hydroforming, and casting.

[0032] Now for reference Figure 1 This illustrates one aspect of a method 100 for forming a casting tool from a tool holder. Method 100 optionally begins at block 102, where computer code is executed to design the part to be formed by the tool. In some aspects, the part design is created by executing computer-aided simulation (CAD) software or by scanning the part using a 3D scanner, and then rendering it to form an electronic representation of the part.

[0033] At box 104, refer to Figure 2A and Figure 2B This illustrates one aspect of tool 200, which designs tool features by executing computer code, which may be computer-aided simulation (CAD) software or other design software. In some aspects, tool 200 features are designed as negatives of parts formed using tool 200. In other aspects, tool 200 features are designed as positives of parts formed using tool 200. Figure 2A The tool 200 shown includes a tool base 202, which is understood herein as a means for fixing, aligning and supporting the forming surface and auxiliary components, such as the cooling lines, electrical components, hydraulic components and mechanical mechanisms of the tool 200.

[0034] Figure 2A and Figure 2BOnly half of the tool base 202, i.e., a single plate, is shown; the other half of the tool base 202 is not shown, but includes features similar to the first half, such as cooling lines (described further here), and in some respects, is another forming surface. Furthermore, depending on the mechanical requirements of the forming process and the complexity of the tool and the part to be formed, each half may have more than one plate. In some aspects, three plates are provided, and up to ten plates can be provided, including wear plates, clamping plates, support plates, ejector plates, etc.

[0035] A forming surface 204 is provided in the tool base 202. A forming surface is understood herein as one or more surfaces used to shape the part. In the illustrated aspect, the forming surface 204 defines a cavity 206, or female mold, shaped like a standard tensile test bar, commonly referred to as a dogbone shape. Furthermore, the tool base 202 includes several auxiliary features. Figure 2A In the aspects shown, a flow channel 210 formed in the tool base 202 connects the cavity 206 to the injection point 212 for introducing a moldable material (such as a polymer) into the cavity 206 and onto the molding surface 204. Furthermore, as... Figure 2B As shown, cooling lines 214 are provided in the tool base 202. Other auxiliary features that may be included in the tool 200 but are not shown include vents, openings in the cavity 206 and the tool base 202 for the ejection system, other injection points, cores, etc. It is understood that the features of the tool base 202, the forming surface 204, and auxiliary features (including cooling lines 214, flow channels 210, injection points 212, etc.) can be designed in one or more CAD files. If the design is done in multiple CAD files, these features can be combined into a single CAD file before designing. It should also be understood that the tool base 202 includes an outer perimeter 216 defined by a number of outer surfaces 218, 220, 222, 224, 226, 228. The outer perimeter 216 defines the overall volume of the tool base 202, in which the various features of the tool 200 (forming surface 204, flow channels 210, injection points 212, and cooling lines 214, etc.) are formed.

[0036] exist Figure 1 Box 106 is shown in the image, and reference is made to... Figure 2A , Figure 2B , Figure 3A and Figure 3B Tool holder 300 is created. It should be understood that tool holder 300 can be directly derived from the design of tool 200, or tool holder 300 can be designed by executing CAD code without referring to the design of tool 200. Tool holder 300 is designed to define the surface features of tool 200, including the outer perimeter 216 and the forming surface 204, as well as auxiliary features such as flow channels 210, injection points 212, cooling lines 214, etc.

[0037] Figure 3A and Figure 3B One aspect of the tool holder 300 is shown, which can be used to form Figure 2A and Figure 2B The tool 200 is shown in the figure. The tool holder 300 can be a male or female mold of the tool 200, depending on whether the tool holder 300 is to be retained as part of the tool 200 or removed from the tool 200. In the aspect shown, the tool holder 300 is retained as part of the tool 200.

[0038] The tool holder 300 includes a holder forming surface 304 defining a holder cavity 306, which provides the forming surface 204 and cavity 206 of the tool 200. Furthermore, the tool holder 300 defines auxiliary features including a holder flow channel 310, a holder injection point 312, and a holder cooling line 314, which provide the tool flow channel 210, injection point 212, and cooling line 214 of the tool 200. The tool holder 300 also defines a holder outer perimeter 316, which forms the outer perimeter 216 of the tool 200. The holder outer perimeter 316 of the tool holder 300 is defined by a plurality of outer surfaces 318, 320, 322, 324, 326, and 328, which form the outer surfaces 218, 220, 222, 224, 226, and 228 of the tool base 202.

[0039] Furthermore, the tool holder 300 defines a void volume 330. The void volume 330 is defined by a number of inner surfaces (including inner surfaces 332, 334, 336, 338, 340) and features formed within the tool holder 300 (such as, not shown, holder cooling lines 314, the inside of holder forming surface 304, holder flow channels 310, injection points 312, etc.). In some aspects, the void volume 330 is in the range of 10% to 95% of the total volume (void or fill volume) defined by the outer perimeter 316 of the tool holder 300, including all values ​​and ranges therein, such as 75% to 90%. The void volume is understood herein as the volume within the range of the total volume, excluding the printed filament.

[0040] It should also be understood that, in the alternative aspect, the tool holder 300 is removed when forming the tool 200, and the inner surfaces 332, 334, 336, 338, 340 and features (such as the inner surface of the holder forming surface 343') are also removed. Figure 3C ), support channel 345' (see Figure 3CThe tool holder 300 and the support injection point 312 (not shown) form the outer surfaces 218, 220, 222, 224, 226, 228 and the forming surface 204, flow channel 210, injection point 212, etc. of the tool 200. If the tool holder 300 includes a support cooling line 314, the cooling line 214 is provided in the tool 200 regardless of whether the support cooling line 314 of the tool holder 300 is removed.

[0041] While the design at boxes 102, 104, or 106 may initially be a two-dimensional representation of a physical object (i.e., the part to be formed at box 102, the tool 200 at box 104, or the tool holder 300 at box 105), computer-aided design software code is executed to convert the two-dimensional design into a three-dimensional design before it is converted into a printable version of the design. At box 108, code is executed to convert the three-dimensional design of the tool holder 300 into a computer numerical control (CNC) design or toolpath file (such as G-code) to slice the design of the tool holder 300 into layers and provide code that can be executed by a 3D printer. It should be further understood that the tool 200, including features of the tool base 202, the forming surface 204, and auxiliary features (including cooling lines 214, flow channels 210, injection points 212, etc.), can be designed in one or more CAD files. If designed in multiple CAD files, these features can be merged into a single CAD file before the design is performed. Similarly, the tool base 302 of the tool holder 300, as well as various features including the holder forming surface 304 and auxiliary features (including holder cooling lines 314, holder flow channels 310, holder injection points 312, etc.) can be provided in one or more CAD files. If the design is done in multiple CAD files, the features can be merged into one file before or after the CAD files are converted into computer digital code software for printing, as described further below.

[0042] Figure 3CA three-dimensional digital representation of a tool holder 300' prior to 3D printing is shown. In this aspect, the three-dimensional representation of the tool holder 300', and the tool holder 300 thus printed, includes a holder forming surface 304', which provides a holder cavity 306' for receiving casting material to be poured into the tool holder 300 to form the tool 200. Furthermore, the illustrated tool holder 300' includes a portion of a holder flow channel 310', a holder injection point 312', and a holder cooling line 314'. Additionally, the illustrated tool holder 300' includes several outer surfaces 318', 320', 324', 326', and 328', which form the outer perimeter 316' of the tool holder 300'. The void volume 330' is defined by the inner surfaces including surfaces 332', 334', 336', and 341', and features formed within the tool holder 300' such as the holder cooling line 342' forming part of the inner surface 341', the inner side 343' (not shown) of the holder forming surface 304, the inner side 345' of the holder flow channel 310', the inner side of the holder injection point 312' (not visible), etc. This representation of the tool holder 300' also includes a plurality of baffles 350', which in some aspects provide additional structural support for the tool holder 300 (see...). Figure 3A and Figure 3B ).

[0043] At box 110, and refer to Figure 4 The computer-controlled code is executed by the 3D printer to print the tool holder 300. The 3D printer feeds a polymer filament 402 in the shape of a nozzle 404 or an extruder, which heats the filament to the point where it begins to soften and melts at least partially on the surface. In some aspects, the polymer used to print the 3D holder includes one or more of the following: polyester, copolyester, polylactic acid, polyamide, thermoplastic polyurethane, acrylonitrile-butadiene-styrene (ABS), acrylonitrile-styrene-acrylate (ASA), high-impact polystyrene (HiPS), polypropylene, nylon (polyamide), polycarbonate, polyetherimide, fiber-reinforced polymer composites, and mixtures or copolymers thereof. In some aspects, the filament polymer is selected to exhibit a softening temperature (such as the VICAT softening temperature), which (e.g., measured by ASTM D 152517e1) is greater than the temperature at which the tool holder 400 is exposed during the hardening process of the casting material (see 552, Figure 5For example, in the range of at least 10°C to 100°C higher than the temperature of the curing process, and in some aspects, up to 300°C higher than the temperature of the curing process. Furthermore, in the aspect where the tool holder 300 is retained in the tool 200, the filament polymer is selected to exhibit a softening temperature (such as the VICAT softening temperature), which (e.g., measured by ASTM D 1525 17e1) is greater than the processing temperature in which the tool holder 400 is exposed when used as a tool (see tool 500). Figure 5 For example, in the range of at least 10°C to 100°C above the processing temperature, and in some respects, up to 300°C above the processing temperature.

[0044] In some aspects, the filament includes additives such as, but not limited to: fibers (including carbon fibers, glass fibers, metal fibers, mineral fibers, or fibers of different polymers whose melting points are relatively higher than those of the polymer forming the filament); and particles, powders, or sheets comprising glass, metals, cellulose, minerals, carbon, or carbon nanotubes. In some aspects, the additives include materials that are susceptible to electromagnetic influence when heated at radio frequencies, including, for example, ferrous metals or carbon nanotubes in the aforementioned forms. The fibers exhibit a particle size in the range of 1 micrometer to 100 micrometers (inclusive); and the particles, powders, or sheets exhibit a particle size of 100 micrometers or smaller (inclusive), including nanoparticles with a particle size of less than 1.0 micrometer or smaller (inclusive of all values ​​and ranges in the range of 10 nanometers to 1 micrometer). In some aspects, such additives are dispersed in the filament 402, while in other aspects they are provided in a coating on the filament core, wherein the coating comprises the same or different polymers as the filament core. The additives are present in the range of 0.1% to 90% of the total weight of the filament, including all values ​​and ranges therein.

[0045] Other additives include pigments, dispersants, surface modifiers, processing aids (such as viscosity reducers or release agents), and flame retardants (such as vinyl-modified siloxanes and organo-modified siloxanes). In some aspects, these additives are dispersed in the filament, or alternatively, they are located in the filament core or filament coating. The additives are present in the range of 0.1% to 25% of the total weight of the filament, including all values ​​and ranges therein.

[0046] Then, following computer digital codes, filaments 402 are deposited layer by layer (layers 408 to 408+n) onto the support surface 406 to form the tool holder 400. As shown, two filaments 402 are used to create the wall 410, and two filaments 402 are used to create the holder cooling lines 412. It should be understood that the number of filaments 402 used to form each feature of the tool holder 400 can vary depending on various factors, such as whether the tool holder 400 will be retained with the tool 200, the mechanical properties required for the features supporting the tool holder 300, and the mechanical properties required for each feature during use if the tool holder 400 is not removed. In some aspects, a range of 1 to 10 filaments (inclusive of all values ​​and ranges, such as 1 to 2 filaments, 3 to 4 filaments, etc.) can be used to form the tool holder features. (Refer to...) Figure 5 Once the tool holder 502 is printed, the void volume 530 within the tool holder 502 at frame 112 is filled with casting material 552. The casting material 552 can be introduced into the void volume 530 through one or more openings 554 in the tool holder 502. The casting material 552 has a shape defined by the inner surfaces 532, 534, 336 (not visible), 538, and 540 of the tool holder 502, as well as features defined by the tool holder 502 (such as cooling lines 514) and features formed inside the molding surface.

[0047] Casting material 552 includes flowable and curable, hardened, or crosslinked materials, such as concrete, ceramics, thermoplastics, foams, gels (such as isoprene gels or thermosetting gels), low-melting-point metals, eutectic alloys, and thermosetting polymers. Thermosetting polymers include, for example, epoxy resins, polyurethanes, acrylic resins, polyesters, vinyl esters, phenols, amino resins, furan resins, benzopyrans, and silicones. In some aspects, casting material 552 includes fillers, such as fibers, powders, granules, or flakes, to relatively improve strength, hardness, thermal conductivity, lubricity, dimensional stability, processability, or combinations thereof. In one aspect, the filler includes fillers susceptible to magnetic, electric, or electromagnetic fields to influence the orientation of the filler before or during curing. In a further aspect, conductive fillers (such as metal particles, metal fibers, carbon particles, carbon nanotubes, or electromagnetic sensors) are present in a sufficient amount in casting material 552 to achieve electrical conductivity, thermal conductivity, or both, after curing. In some respects, these susceptible fillers can also aid the curing process by heating the casting material with electric or electromagnetic energy, including direct current (DC), radio frequency, microwave, and infrared heat.

[0048] The fiber filler used in casting material 552 includes fibers of carbon fiber, glass fiber, metal fiber, mineral fiber, or various polymer materials (whose melting point is relatively higher than that of the polymer forming the filament). The fiber filler exhibits a length ranging from 1 micrometer to 10 millimeters, including all values ​​and ranges therein, such as from 1 micrometer to 100 micrometers, from 100 micrometers to 3 millimeters, and so on. Powders, particles, or flakes include glass, metals, cellulose, minerals, fluoropolymers, graphite, carbon, molybdenum disulfide, and ceramics (such as boron nitride and aluminum nitride), as well as carbon nanotubes, wherein, in some aspects, the particle size of the powder, particles, flakes, or nanotubes is 100 micrometers or less, including nanoparticles with a particle length less than 1.0 micrometer. In some aspects, the filler is present in the range of 1% to 95% of the total weight of casting material 552, including all values ​​and ranges therein, such as 25% to 90%, 20% to 50%, and so on.

[0049] In some aspects, the tool holder 502 is treated before the casting material 552 is introduced, such as by applying a release agent to the tool holder 502 or by machining the tool holder 502 before the casting material 552 is added. In additional aspects, the casting material 552 is treated when the casting material is filled into the tool holder 502, or once the casting material 552 has been added to the tool holder 502. For example, when the casting material fills the tool holder 502, or after filling the tool holder 502, a magnetic field or electrostatic field is applied to the casting material 552, causing filler particles susceptible to such a field to orient within the casting material 552. In a further aspect, the tool holder 502 is treated after the casting material 552 is added, such as by vibrating the tool holder 502 to assist in the precipitation of the casting material 552 and to reduce air bubbles in the casting material 552 before hardening. In some aspects, casting methods including vibration casting, vacuum casting, pressure casting, or centrifugal casting may be employed to assist in full-density filling of the support, elimination of air voids, or working with high-viscosity or thixotropic casting materials.

[0050] The casting material 552 is hardened to form a solidified shape. In some aspects, hardening is caused by chemical reactions in the casting material, such as hydration, curing, vulcanization, or irradiation. In aspects involving concrete, hardening is caused by hydration, wherein water in the concrete mixture forms chemical bonds with cement in the concrete mixture. In aspects involving thermosetting polymers, hardening is achieved by crosslinking of polymer chains initiated by the addition of a crosslinking agent, heating, pressurization, pH alteration, irradiation, or a combination thereof. In some aspects, thermoplastic polymers may also be used as casting material 552 and crosslinking occurs upon exposure to light in the electromagnetic range, such as electron beams, gamma rays, or ultraviolet light.

[0051] It should be understood that in some aspects, such as, Figure 5 As shown, the hollow channel 515 in the cooling line 514 allows for the introduction of cooling or heating to manage the temperature of the casting material 652 within the tool holder 502 during hardening. Thermal management can be facilitated by introducing either gas or liquid into the channel of the cooling line 614, which is either hot or cold, to introduce or reduce heat, respectively.

[0052] Figure 6 One aspect of a casting tool 600 is shown, including a 3D-printed tool holder 602 and a hardened casting material 652 (concrete in this example). As shown, the casting material 652 has a shape defined by inner surfaces 632, 636, 640 (not visible), and 641. Although not illustrated, if a baffle (see...) Figure 3C The baffle 350' is included in the tool holder 602, and the casting material 652 at least partially, and in some respects completely, covers the baffle. Where cooling lines are present, such as Figure 5 As shown, the casting material 552 has the shape of a cooling line 514, wherein a hollow channel 515 is defined by the cooling line 514.

[0053] At box 114, and refer again Figure 5 The 3D printing tool holder 502 can be optionally removed from the outer surface of the casting material 652, and then used itself as the forming tool. In some aspects, the tool holder 502 can be removed mechanically or chemically. For example, in some aspects, the tool holder is removed by machining or otherwise cutting off the holder. In a further embodiment, the tool holder 502 is retained in the tool. Regardless of whether the outer surfaces 518, 520, etc. of the tool holder 502 are removed, in some aspects the portion of the tool holder forming the cooling conduit 514 is removed, or in others it is retained.

[0054] exist Figure 1 At frame 116, then optionally a finishing tool 500. In some aspects, if a cooling line 514 exists (which may itself be porous), leakage is prevented when coolant is introduced by providing an anti-friction coating to reduce scale buildup or to reduce the porosity of the cooling line 514. However, it should be understood that the casting material 552 (particularly in the case where the casting material is a polymer) seals the cooling line 214, so additional sealing of the cooling line can be omitted. In some aspects, and referring to Figure 2A , Figure 2B and Figure 4 The molding surface 204 is sealed to reduce gaps 420 that may exist on the surfaces between layers 408 and 408+n. Figure 4(As shown in the figure). In a further aspect, the forming surface 204 is plated or coated with an anti-stick coating, such as nickel, chromium, or nickel-PTFE, to prevent the parts from sticking together during the forming process. In an additional aspect, the forming surface 204 and other outer surfaces 218, 220, 222, 224, 226, 228 are polished or otherwise machined to reduce roughness or other unwanted features. In addition to sealants, coatings, and machining, other finishing operations may be performed, such as tapping cooling lines. Furthermore, as mentioned above, tools 200, 500, 600 can be assembled to include other plates, ejection systems, heated gate assemblies, or other features.

[0055] Casting tools 200, 500, and 600 are used to form parts, and the process flow includes: injection molding, blow molding, compression molding, rotational molding, composite material lamination, extrusion molding, vacuum forming, hydroforming, and casting. As mentioned above, the tool includes, for example, a mold, die, jig, model, or fixture. In some aspects, the parts are formed from thermoplastics, thermosettings, woven fabrics, non-woven fabrics, or various forms of metal (including sheet metal, pipe, or other profiles). For example, in some aspects, Figure 5 The casting tool 500 with tool holder 502 is used in the injection molding process, and in some aspects, Figure 6 The casting tool 600, after removing the tool holder 602, is used for hydroforming processes or for composite material lamination.

[0056] The casting tool and the method for forming the casting tool from a 3D-printed scaffold by extruding material disclosed herein have several advantages. These advantages include the ability to relatively reduce the mass and density of the mold before adding casting material. These advantages also include the ability to relatively reduce the time required to print the tool and form the 3D-printed tool compared to a 3D-printed tool filled with printing filaments. These advantages also include the ability to relatively reduce the cost of the 3D-printed portion of the tool compared to a 3D-printed tool including 3D-printed filler. These advantages also include the ability to utilize relatively low-performance, low-cost resins because the 3D-printed portion of the tool is supported by a relatively high-performance casting material. These advantages also include the ability to reduce the number of processing steps because the tool scaffold can be filled and the cooling lines sealed in a single step.

[0057] The descriptions in this disclosure are merely exemplary in nature, and any changes that do not depart from the spirit and scope of this disclosure will fall within its scope. Such changes should not be considered as departing from the spirit and scope of this disclosure.

Claims

1. A method for forming a tool, the method comprising: A 3D printed tool holder, wherein the tool holder defines a void volume and a holder forming surface; The void volume is filled with casting material; Harden the casting material; and Seal the forming surface of the bracket; The tool holder further defines a holder cooling line, and the method further includes sealing the holder cooling line.

2. The method of claim 1, further comprising treating the tool holder before filling the void volume with the casting material.

3. The method according to claim 2, wherein, Processing the tool holder includes machining the tool holder.

4. The method according to claim 2, wherein, Processing the tool holder includes applying a release agent to the tool holder.

5. The method of claim 1, further comprising applying a magnetic field or electric field to the tool holder while filling the void volume with the casting material.

6. The method according to claim 1, further comprising vibrating the tool holder after filling the void volume with the casting material.

7. The method according to claim 1, wherein, A casting method is selected from the group of casting methods consisting of vibration casting, vacuum casting, pressure casting and centrifugal casting, and the casting material is used to fill the void volume.

8. The method according to claim 1, wherein, Hardening the casting material includes subjecting the casting material to a chemical reaction.

9. The method according to claim 8, wherein, The casting material is concrete, and the casting material undergoes a chemical reaction, including hydration.

10. The method according to claim 8, wherein, The casting material includes thermosetting plastics, and the chemical reaction of the casting material includes crosslinking the casting material.

11. The method according to claim 8, wherein, The chemical reaction of the casting material includes sulfidation of the casting material.

12. The method of claim 1, further comprising removing the tool holder from the casting material after hardening.

13. The method according to claim 1, wherein, The tool holder further defines a holder cooling line; and the method further includes introducing a cooling or heating fluid or gas into the holder cooling line while hardening the casting material.

14. The method of claim 1, further comprising generating computer numerical control code from the CAD file, wherein, The computer digital control code is used for 3D printing tool holders.

15. The method of claim 14, further comprising merging multiple CAD files to generate the computer numerical control code.

16. A tool formed by the method of claim 1, comprising: 3D printed bracket; Hardened casting material within the 3D printed scaffold; as well as The support molding surface defined by the 3D printed support.

17. The tool of claim 16, further comprising an auxiliary feature defined by the 3D printed scaffold, wherein the auxiliary feature includes scaffold cooling lines.

18. The tool according to claim 16, wherein, The 3D printing tool holder includes multiple baffles.

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