Development of new metal/polymer materials for rapid tooling using Fused deposition modelling

This paper presents the development of a new metal/polymer composite material for use in fused deposition modelling (FDM) process with the aim of application to direct rapid tooling. The material consists of iron particles in a nylon type matrix. The detailed formulation and characterisation of the tensile properties of the various combinations of the new composites are investigated experimentally. The feedstock filaments of this composite have been produced and used successfully in the unmodified FDM system for direct rapid tooling of injection moulding inserts. High quality plastic parts have been injection moulded using the inserts. The work represents a major development in reducing the cost and time in rapid tooling. (C) 2004 Elsevier Ltd. All rights reserved.