Electroplated Molds

Lasers are used to produce the master which is used for mass production, e.g., in Laser LIGA [399] (LithographieGalvanoformungAbformung/lithog-raphy-electroplating-molding). 

Molds from aluminum (aluminum casting and CNC-milled) or sheet steel are used today for rotational molds. Electroplated molding has established itself for special rotational molds for PVC plastisols. There are also a couple of other materials that can be used in prototype production. 

In electroplated molds, a model is molded to the smallest detail (see Section 4.3). The positive model, which corresponds to the finished article, is therefore the basis for electroplated rotational molds and slush molds. The necessary finesse, such as surface quality, dimensional tolerances, mounting parts have to be determined. For example, it is possible in prosthesis manufacture to use rotational molds to get an exact impression of which the inner contour is an impression of the human skin. This shows the precision of electroplated molds and the art to manufacture sufficient models made from resistant materials. 

Therefore, single-parted rotational and slush molds are prerequisite and are provided with openings out of which the elastic components are ejected off. Ejecting components in electroplated molding is also done through small mold openings. Therefore, model materials are used that can be mechanically or chemically destroyed. 

For economical mass production of doll parts and toy animals, multiple identical electroplated molds are necessary. Therefore, the models are done as follows ... 

FIGURE 1.181 Model for the manufacture of an electroplated mold for the production of anatomical demonstration objects (e.g., eye)... 

In regards to the heat transfer material induced disadvantages of higher wall thicknesses in comparison to steel sheet, the thermal conductivity is offset by aluminum (for wall thicknesses of electroplated molds see Section 4.3). 

FIGURE 1.185 Shaping contour with double electroplated mold to produce two instrument panels at the same time... 

FIGURE 1.187 A complete electroplating mold to use in systems with temperature control using thermal oil... 

For heating and cooling, different process systems can be used that need adapted electroplated mold shells ... 

In order to meet the great demands of application technology and the design department on the construction, surface structures, dimensional stability of the slush mold skins, electroplated molds are made available. The goal is reached by using a complex and expensive model technology. Figure 1.188 shows the principle path from CAD data to the finished electroplated mold shell. 

Steps for the Production of Electroplated Molds for the Slush and Spray Technology... 

FIGURE 1.188 Process steps for the manufacture of models and electroplated molds... 

After final acceptance and release through the customer, the so-called work-silicone can be casted. Out of this silicone, five to six positive bath models made from epoxy resin can be produced. Then, the work silicone has to he renewed. Because the quality of the hath model determines the quality and dimensional stability of the electroplated mold, another control survey of the CAD data will he necessary. In spite of many process steps, in the area of mounting components and attachments, a tolerance (towards the CAD data) of 0.2 mm and in the open space areas of 0.5 mm should be maintained. To meet these tight tolerances, the highest demands are placed on the mold making (Figure 1.189). 

Electroplating mold inserts for transfer molding of artificial teeth made from acrylic material are also among the molds with an irregular progress of the parting line. 

These electroplating molds, of which larger quantities are produced annually, have significantly contributed to the introduction of more efficient production methods in this special field. 

The unique electronic stmcture of CNTs makes them ideal candidate materials for composite devices. SWNT/poly (3-octylthiophene) composite possesses properties suitable for use in photovoltaic cells.Composites with PMPV have been reported to be effective in organic light-emitting diodes as electron transport layers.Actuators based on SWNT/Nafion composites have potential applications as microswitches and artificial muscles. CNT/polyimide composites have been investigated for use as ultrafast optical switches. Such materials exhibited optical delay times less than 1 ps at a wavelength of 1.55 pm and showed great potential as all-optical switches. MWNTs dispersed in a photoresist epoxy can be applicable in the production of microelectromechanical systems such as electroplating molds, sensors, and aauators. ... 

Micro injection molding has the most established tooling architecture of these four processes. The tooling consists of a metal, siheon (prototyping) [3], or electroplated mold with the associated machinery for high tempaature extrusion of the polymer. Injection molding machines and the dies associated with them tend to be large and costly. 

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