نبذة مختصرة : International audience ; We propose in the paper a rapid prototype tooling technique. The process is based on the use of a high velocity, electric arc metal spray thoroughly atomised on a master model in order to make a shell. The mold is realised by placing the sprayed alloy into a frame and reinforcing it with appropriate material. The paper is organised in three main chapters. In the first one we describe the spray operations. The tool/moldmaking technique presented is a process to reproduce shapes very accurately. Given any model or pattern made of materials – such as SLA, metal, wood, wax, cloth or plaster – a metal shell can be build up around it to desired thickness. We describe and comment the tasks leading to the shell making. The second chapter deals with the realisation of the mold itself. In most cases, the spray alloy shell must be reinforced with the proper backup system but some applications like large sprayed molds can be backed with a laminating system such as fibreglass, kevlar or graphite. In the last chapter, we expose the application fields of this new technique especially in term of product and process validation. We focus on the natural links with Stereolithography and Solid freeform manufacturing which propels the spray metal tooling technique into one of the fastest, most economical way to produce actual material. By comparison with conventional processes, we show how fabrication time and costs are dramatically reduced by integration of this new moldmaking method. Finally, we present the limits of the technique and the perspective of work and further research.
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