Method of directly making rapid prototype tooling having free-form shape
AssigneeFord Global Technologies, LLC
InventorsFurqan Z Shaikh, Howard Douglas Blair, Tsung-Yu Pan
Life of this patent
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Abstract
A method and apparatus for directly making rapid prototype tooling from a computer model having a free-form shape. The method steps comprise essentially: (a) machining a soft metal tooling base so as to contour at least one free-form surface in conformity with the computer model; (b) cold-gas dynamic spraying the contoured surface to form superimposed impact welded metal particle layers, the layers consisting of at least one thermal management under-layer comprising primarily copper, and at least an outer wear resistant layer comprising primarily tool steel.
Claims11
Method of directly making a wear resistant article from a computer model having a free-form shape, comprising:
- (a) machining a soft metal article base so as to contour at least one free-form surface conforming essentially to said computer model;
- and;
- (b) cold-gas dynamic spraying the contoured surface to form superimposed impact-welded metal particle layers thereon, the layers consisting of at least one thermal management under-layer comprising primarily cooper, and at least one outer wear-resistant layer comprising primarily tool steel.
A method of king a wear-resistant article from a computer model having a free-formed shape, said method comprising:
- machining an article base to form a contoured surface conforming essentially to the computer model, said article being made of a soft metal;
- and
- cold gas dynamically spaying metal particles in an un-melted condition to form superimposed impacts-welded metal particle layers on the contoured surface, the layers consisting of at least one thermal management under-layer comprising essentially copper, and at least one outer wear-resistant layer comprising primarily tool steel.
Dependencies are inferred from the claim text.