Application of Techniques and Systems for Additive Manufacturing in Rapid Tooling

The paper presents the integrated application of additive manufacturing and reverse engineering technologies for the rapid tooling for two-component plastic casting, as a faster and cheaper approach than injection moulding, particularly for small-scale production of plastic parts or spare parts when CAD models and technical documentation are not available. An optical scanner based on white structured light was used for 3D digitalization of the selected plastic gas handle. Based on point cloud, a master CAD model was prepared for the design of casting tool cavities. The design of the master model was verified through its additive manufacturing using FDM technology. After repeated 3D digitization of the printed master model and comparison with the original part, the master CAD model was redesigned. The process of two-component casting in tools obtained by additive FDM manufacturing was realized successfully and verified by comparing the cast and original gas handle.