Polymer Shell Forming Tool With Reusable Metal Backfill
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current forming tools made from traditional tool steel for prototype and mass production are costly and require significant labor and material waste, as they are machined using CNC methods, despite not needing the same durability as mass production tools.
Innovation Solution
A forming tool is created using additive manufacturing with a polymer shell and a solid phase backfill material, where the polymer shell is contoured for shaping and the backfill material provides rigidity and strength, allowing for reduced material usage and cost-effective production by reusing the backfill material across multiple tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional tool steel is used for forming tools, then strength and durability are improved, but manufacturing cost and labor time increase significantly
Solution Approach 1:
The patent uses a composite structure combining polymer shell and metal backfill material. The polymer shell provides the forming contour while the metal backfill provides structural strength, eliminating the need for expensive tool steel while maintaining required mechanical properties.
Solution Approach 2:
The tool is divided into two functional segments: the polymer shell that defines the forming geometry and the metal backfill that provides structural support. This segmentation allows each component to be optimized for its specific function rather than requiring the entire tool to be made from expensive tool steel.
2Strength
If CNC machining is used to manufacture forming tools, then strength is maintained, but material waste and labor time increase
Solution Approach 1:
The patent changes the material parameters by using polymer instead of tool steel for the shell portion, and utilizes additive manufacturing parameters to build the tool geometry directly, eliminating the subtractive machining process that generates significant material waste.
Solution Approach 2:
The patent applies different material qualities to different regions of the tool: the polymer shell provides the necessary surface quality and contour accuracy, while the metal backfill provides localized structural strength only where needed, rather than using expensive material throughout the entire tool.
3Reliability
If prototype tooling is made with the same durability as mass production tooling, then durability is improved, but cost increases without necessity
Solution Approach 1:
The patent changes the durability parameter by using a composite structure where the metal backfill provides sufficient structural reliability for prototype applications without requiring the full durability specifications of mass production tooling, thereby reducing manufacturing cost while maintaining adequate performance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces production time and material waste, while maintaining the necessary strength and durability for forming operations, allowing the backfill material to be reused across multiple tools, thus spreading its cost and reducing overall tooling expenses.
Implementation Method 1
A molten backfill material is arranged at the second side of the polymer shell. The molten backfill material is solidified to thereby form a solid phase backfill material
Implementation Method 2
Low melting temperature metal backfill for additively manufactured tools
Data Source
AI summary
A forming tool including an additive manufactured polymer shell defining a first side and an opposite second side. The forming tool includes a support structure mechanically connected to the second side of the shell. The support structure may be formed by pouring a molten backfill material into the shell, and solidifying the backfill material. The backfill material includes a low melting temperature metal, fusible alloy, or other element. The solidified backfill material has a strength and rigidity greater than the polymer used to make the shell. The first surface of the shell includes a complex surface for bringing into contact with a material in a stamping process to form a stamped part.