9360935 Wise Three methods are proposed for making net shape high temperature mandrels to form chemically vapor deposited nickel shell tooling based on solid freeform fabrication (SFF) models. The three methods are distinguished by the number of generations or replications the nickel shell will be from the SFF model: three, two or one. The three and two generation methods use chemically bonded ceramic materials to form the mandrel because of their compatibility with SFF models coupled with precision, quick and easy formability, thermal stability and thermal conductivity. The single generation method will require the development of a high temperature SFF model. The shells formed from these mandrels will be incorporated into injection molds by backing them with CBC and mounting them in a standard mold frame. The mold will be tested for part precision and cycle time. The anticipated application of the technology, as defined, is the tooling industry and specifically the matched die molding industry. If successful, enhanced automation of complex mold production could improve the worldwide competitiveness of the United States tool and die industry and dramatically reduce costs for any industry that relies on molded parts, particularly those with production runs of less than 25,000 parts.
