Shelling strategies to save time in a rapid tooling process

Selective laser sintering can be used to manufacture injection mould inserts using an indirect metal laser sintering process, such as the RapidTool™ process commercialised by 3D Systems. The volume of material to be laser processed for insert manufacturing is very high when compared to that for plastic prototype manufacturing. Consequently, the time involved in the laser processing is also very long. This paper describes the development and assessment of shelling strategies to be applied in an indirect rapid tooling process aimed at reducing time in the process. The feasibility of the shelling idea has been confirmed and although the scanning system offers some limitations to the idea two strategies are presented as successful, open shell and closed shell, with a great potential to save time.