Spray-Formed Tooling with Micro-Scale Features

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Molds, dies, and related tooling are used to shape many of the plastic and metal components we use every day at home and work. Traditional mold-making practices are labor and capital equipment intensive, involving multiple machining, benching and heat treatment operations. Spray forming is an alternative method to manufacture molds and dies. The general concept is to atomize and deposit droplets of a tooling alloy onto a pattern to form a thick deposit while imaging the pattern’s shape, surface texture and details. Unlike conventional machining, this approach can be used to fabricate tooling with micro-scale surface features. This paper describes ... continued below

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McHugh, Kevin June 1, 2010.

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Molds, dies, and related tooling are used to shape many of the plastic and metal components we use every day at home and work. Traditional mold-making practices are labor and capital equipment intensive, involving multiple machining, benching and heat treatment operations. Spray forming is an alternative method to manufacture molds and dies. The general concept is to atomize and deposit droplets of a tooling alloy onto a pattern to form a thick deposit while imaging the pattern’s shape, surface texture and details. Unlike conventional machining, this approach can be used to fabricate tooling with micro-scale surface features. This paper describes a research effort to spray form molds and dies that are used to image micro-scale surface textures into polymers. The goal of the study is to replicate textures that give rise to superhydrophobic behavior by mimicking the surface structure of highly water repellent biological materials such as the lotus leaf. Spray conditions leading to high transfer fidelity of features into the surface of molded polymers will be described. Improvements in water repellency of these materials was quantified by measuring the static contact angle of water droplets on flat and textured surfaces.

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  • PowderMet 2010,Ft. Lauderdale, FL,06/27/2010,06/30/2010

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  • Report No.: INL/CON-10-18503
  • Grant Number: DE-AC07-05ID14517
  • Office of Scientific & Technical Information Report Number: 984543
  • Archival Resource Key: ark:/67531/metadc1013443

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Office of Scientific & Technical Information Technical Reports

Reports, articles and other documents harvested from the Office of Scientific and Technical Information.

Office of Scientific and Technical Information (OSTI) is the Department of Energy (DOE) office that collects, preserves, and disseminates DOE-sponsored research and development (R&D) results that are the outcomes of R&D projects or other funded activities at DOE labs and facilities nationwide and grantees at universities and other institutions.

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  • June 1, 2010

Added to The UNT Digital Library

  • Oct. 14, 2017, 8:36 a.m.

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  • Nov. 3, 2017, 5:24 p.m.

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McHugh, Kevin. Spray-Formed Tooling with Micro-Scale Features, article, June 1, 2010; Idaho. (digital.library.unt.edu/ark:/67531/metadc1013443/: accessed April 25, 2018), University of North Texas Libraries, Digital Library, digital.library.unt.edu; crediting UNT Libraries Government Documents Department.