For many years, companies have been seeking ways to reduce the time and the cost needed to make metal tools used for stamping, injection molding, blow molding, thermoforming, die casting, and other applications. There have been improvements, but tools essentially continue to be made conventionally by chipping away at metal block to create net shapes. Research efforts by Ford Motor Company have resulted in several breakthroughs related to rapid tooling. Specifically, tools and other objects now can be made by thermal spraying metal onto a patterns made from ceramics, sand and other substrates. Ford calls this Sprayforming.

When Ford purchased Sprayform Holding Ltd, it acquired a 20-year history in Sprayforming. This enabled Ford to develop equipment and technology to rapidly manufacture production tools and dies - it's not just for prototyping. Where others are able to manufacture relatively thin shells of less than a quarter inch, Ford's Sprayforming technology produces dies up to three inches thick that are capable of withstanding the most demanding metal stamping and injection molding applications

 

Sprayforming Process

Designers create a CAD file of the article to be formed.

A model of the article or tool is made from REM, plaster, fiberglass, silicon rubber or stereo lithography.

A ceramic or sand cast is made from the model.

The cast is placed within a Sprayforming cell.

Spray metal is deposited atop the cast to from the article or tool in a near net-shape. In some applications, little or no additional surface finishing is needed.

The tool is trimmed to the desired dimensions using a water jet or other cutting tool.

The Sprayformed shell is attached to a composite-metal backing.

Sample Tools and Articles

Form Dies

More than one million transmission turbine blades were produced using Sprayform tools.

While the existing Sprayforming cells are limited in the size of articles they can produce, larger articles may be made by combining smaller pieces. This inner hood was used to stamp several hundred prototype stampings.

Make 60,000 production latch covers.

An aluminum trim die.

 

Videos of the Process

David E. Cole (Part 1). Director of the Center for Automotive Research (CAR) 3.5 MG
Metal Spray. 1.5 MG
Waterjet. 1 MG
Epoxy Backfill. 1.3 MG
David E. Cole (Part 2). 5.6 MG

Benefits Summary

Sprayforming metals such as zinc and zinc-iron is a well established process, Ford's breakthrough is the capability spray iron and steel in bulk with little or neutral internal stresses. Prior attempts at spraying iron and steel resulted in parts that warped or buckled. Sprayformed articles with low or neutral internal stresses resist deformation and cracking. Depending on the application, the Sprayforming process can produce articles to near net-shape with little or no post-process finishing required.

Ford has facilities in place that can produce tools up to 3 ft. x 3 ft. Larger articles may be produced by joining section as shown by the inner hood die.

Sprayforming technology offers significant cost and time reductions when compared to conventional CNC machining processes. While it is especially well suited for prototype and low-volume tooling, it is also capable of high-volume production applications.

Features

Cost: (about 10-15% less than conventional tools)

Timing: (The sprayed shell may be produced in much less time than CNC components. When Sprayforming is combined with other techniques, dramatic time savings are achievable).

Materials: (Sprayform tools have hardness levels equal or better than convention tools)

Flexibility: (features such as cooling lines, actuators, slides or fine detail features may be formed into the tool)

Repeatability: (exact copies of tools may be made from an existing pattern or CAD file)

Reparability: (Sprayform tools may be welded)

Surface Finishes: (little or no additional finishing needed in non-Class A applications. Sprayformed tools may be machined or plated in a fine surface finish is needed)

Elimination of prototype tools: ((Sprayformed steel tools suitable for production uses may be made for less than the cost of prototype kirksite tools.

 

Advantages

Only Ford Sprayform tooling provides the durability needed for production applications. Ford Sprayform tools are designed to replace Production tools previously made through CNC milling.

Applications

• Stamping Tools
• Injection Molding Tools
• Blow molding Tools
• Casting and Die Casting Tools
• Thermoforming Tools
• Other applications that machine articles from steel billet

Development Status

Ford has been using Ford Sprayform tooling in large-scale production for several years. The technology is proven in the most demanding applications.

Licensees

FGTI has licensed ten tooling or equipment manufacturers. Including: Atlas Tool, Praxair Surface Technologies, Inc., Tomco Tool & Die. and Norvac

       

Patent Information

Clicking on the link will take you to the United States Patent And Trademark Office where more information is given about that particular patent. By clicking on any of the links below you are leaving a Ford site and being redirected to a Non-Ford site. We encourage you to review the privacy statement on any site you visit before submitting any personal information.

Collaboration Options

FGTL is seeking strategic partners for plastic molding equipment and tooling. Development partners that make a significant investment in the technology will be entitled to participate in a Strategic Partners Team to review and share new developments from different industries. Strategic Partners will also be offered a reduced royalty in exchange for their investment in the technology.

Terms

Available upon request

Licensee Support

Ford maintains two facilities for testing, prove-out and commercial tooling production. Licensees will be provided access to these facilities to learn about the technology and to develop pilot projects until their facilities are operational.

Ford Technology Code

Manufacturing, M632

 

Articles

"Rapid Tooling Technology from Ford Country", Raymond E. Chalmers, Manufacturing Engineering Magazine, Vol.127, No.5, p.36-41 (107KB Adobe Acrobat PDF file)

"New Tooling Tech Promises Major Time, Cost Savings", J.Szuba, Presented at Ward's AutoWorld 2001 Management Briefing Seminars, Traverse City, MI, 7-Aug-01 (External Web Link)