Rapid tooling for optical molding utilizing Cast It(TM) 2000 aluminum epoxy alloy

Rapid tooling is a process that uses unconventional tooling techniques to construct parts. Numerous tooling methods have developed and evolved over the years. One particular type of rapid tooling that is starting to gain wide spread acceptance is the use of cast aluminum epoxy alloys. This particular paper explores the use of wax patterns and Ciba Specialty Chemicals Cast It™ 2000 aluminum epoxy alloy for optical molding. The 70% aluminum, 30% epoxy alloy allows for the quick generation of prototype cavities and molds. With the use of a CAD system, 3D Systems Thermojet® solid object printer, and Cast It™ 2000 resin, it is possible to generate cavities and functional optical parts within 72 hours.; Results indicate that optical tooling and lenses can be constructed out of Cast It™ 2000 resin using wax patterns in 72 hours, provided that diamond turned aluminum inserts are used for the optics. Piece parts that fall within the dimensional accuracy of +/−.005&inches; is achievable using this rapid tooling process. Short production runs, part performance evaluations, statistical analysis, process set up and design validation can all be accomplished at a very low cost before production tooling is constructed.