High accuracy of cavity dimensions, form and surface definition
Reasons to use
- Only method available for creation of tools with extremely complex undercuts
- Cost effective method for complex mouldings
- Well suited to small to small/medium sized mouldings
- High accuracy of cavity dimensions, form and surface definition
- Well suited to higher volume applications as much of the cost of the manufacture of the first tool is not repeated for subsequent tools
- Can receive a huge range of surface finishes usually produced by laminating onto the master model.
Method of manufacture
Secondary wax models are produced from a master model. The wax models are put into an electroplating bath and receive a coating of nickel (0.5 – 1 mm) followed by a coating of copper (3 – 5 mm), after which the wax is melted out to create a nickel / copper shell. Additional metallic components (mounting frame, flange plates, etc.) are then brazed onto the shell to create the mould tool.
This method is used mostly (but not exclusively) for its ability to create extremely complex undercuts combined with very high surface definition. Good examples are automotive dashboards, grab handles and armrests; dolls’ heads and torsos; and vehicle handbrake and gear lever gaiters.