Tools to Die For

This article discusses the rapid solidification process (RSP) which is being developed by Idaho National Engineering & Environmental Laboratory, a US Department of Energy research lab in Idaho Falls. This process drastically lowers the costs and lead times of production tools. In an approach that is radically different from conventional tool making, in which a mold core and cavity are machined from a block of steel, RSP equipment creates a shape by spraying molten metal onto a pattern, faithfully reproducing the pattern's shape, details, and texture. Tools can be completed in as little as three days, and are suitable for both prototyping and production runs. RSP differs significantly from other commercial spray metal techniques, broadly known as thermal spray. RSP tooling can undergo either conventional heat treatment or low-temperature heat treatment known as artificial aging. Artificial aging allows the tailoring of steel properties, such as hardness, toughness, and thermal heat resistance, without the risk of tool distortion.