Success Story
Qi Hui Tooling Co. used a traditional mold design and machining was based on inaccurate and time consuming manual operations, including sculpting, manual molding, parting, and scanning. The STL-based mold making needed a digital solution to complete the design to manufacturing process more effectively and accurately.
Priority project goals identified were as follows: 1) Complete the parting surface and mold design modeling by Autodesk PowerShape. 2) Complete the toolpath programming of mold manufacturing by Autodesk PowerMill. 3) Ensure that the toolpaths are able to machine the mold by a very small cutting tool and with very good surface finish, as manual polishing after machining is prohibited.
Primary solutions deployed and benefits enjoyed were as follows: 1) PowerShape provided the solution to analyze the possible undercut, so that the parting curve can be generated at the best location. 2) By using the total modeling capability of PowerShape, the STL-based toy model can be trimmed into different parts according to the parting curve. 3) Created reasonable parting surface by the advance surface modeling capability of PowerShape. 4) With the excellent toolpath programming capability (especially the precise stock model generation) of PowerMill, the small cutting tool can now accurately machine the rest materials without any overload in cutting. 5) The collision detection and avoidance capability of PowerMill can guarantee gouge-free toolpaths with the most appropriate tool overhang.
By using PowerShape and PowerMill and the developed PowerMill-based applications, the STL-based mold design and manufacturing can now be completely performed in a digital way. Due to the accuracy that can be achieved by the digital CAD/CAM based solution, small cutting tools can be extensively used so that the resolution of mold can be greatly enhanced. The machine mold also has highly improved surface finish quality, so that manual polishing after machining is not required anymore. Moreover, the customized PowerMill-based application has further improved the toolpath programming process so that now it becomes a highly effective systematic process. The application also can capture the machining know-how for cultivating an in-house knowledge hub for machining of new mold materials. This is crucial to the shortening of the mold making cycle. The developed CAD/CAM solution is one of the critical factors to realizing the rapid expansion of the client's business.
Qi Hui Tooling Co. has been able to realize their vision in creating a disrupting digital toy mold design and production process. DelcamHK has collaborated with the client as a professional CAD/CAM Solution Provider, consultant and customized application developer. This has created a win-win-win situation for client, DelcamHK and the CAD/CAM solution of Autodesk (PowerShape and PowerMill).
Project summary
Duration & delivery
Autodesk solutions
Customer industry
PowerMILL customized Apps to complete CAM programming in 10 minutes
For the products that customer needs to quickly produce, there is currently no commercially available machine tool that can produce directly and quickly. They must develop their own special machine tool and CAM programming system.
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