Abstract
Rapid Prototyping and Tooling (RP&T) technologies are applied extensively and intensively in the industry and their importance is increasing because it reduces the development time and cost required for product prototyping and injection moulding dies and EDM electrodes tooling. Namely additive technologies are getting interest due to the possibility to build a component by adding material. The paper addresses the study and application of Direct Metal Laser Sintering (DMLS) of copper alloys for Rapid Tooling of dies for thermoplastic polymer injection moulding. Specific samples have been designed by CAD, in order to be representative of the geometrical and morphological features and functional characteristics of the dies. The main limitations of DMLS prototypes are relevant to surface properties as porosity, roughness, hardness, corrosion, erosion and wear resistance. The study takes into consideration the characterization and improvement of DMLS surface properties in order to meet their functional requirements. To this purpose, different surface treatments have been studied and applied, as blasting and peening, resin infiltration, electroless nickel plating. Sample surfaces has been fully characterized and analysed, as obtained by DMLS, and after surface treatments. 3D surface roughness and microgeometrical morphology and porosity and microhardness properties have been systematically investigated.
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