The technique reduces the cycle time time it takes to make a mold or to make the part by as much as 25 percent and reduces the manufacturing costs by as much as 50 percent . 

"These improvements would apply to all blow mold, and foam-mold and some sheet molding applications," according to Dr. William Jones, engineering director for Metallamics, where the technology is being prototyped under contract to a major producer of foam-molded automotive seating. In addition, production molds are planned for polyethylene and PET bottles, as well as sheet molding products. 

For best quality and efficiency, molds need to be maintained at a constant temperature and achieve even heat distribution. The new manufacturing technique uses a variety of thermal plasma techniques to coat the surface of specially designed molds with a layer of specific metals. This improves the heat transfer efficiency of the mold, thereby reducing temperature variation in the mold, which improves both molded product economy and quality. 

Current mold technology does not permit one to achieve a uniform temperature or heat transfer. These variations cause less than optimum cycle time and finished product quality flaws caused by variations in heat distribution from the mold have commonly shown up as flaws in finished products. 

"There are thousands of molds made in manufacturing each year. This new technology for mold manufacturing could modify the entire market. The term is tossed around quite a bit, but we believe this technique will truly be a 'paradigm shift' for mold-making technology," Jones said. 

Thermal plasma spraying is a procedure commonly used to apply the feed material for example, an aluminum alloy to a substrate, the base material to which the molten spray adheres. While thermal plasma spraying is not new, its use for coating molding materials in this new fashion is unique. 

Metallamics, located in Traverse City, Mich., focuses on the commercial application of advanced materials, and has been working with the ORCMT Thermal Spray Technology Center and center manager Roland D. Seals, under a deployment/user facility agreement that allows companies hands-on access to the facilities and equipment of ORCMT. 

"The association with ORCMT has been of tremendous assistance to the company. It has given us access to exceptional technical personnel and is one of the foremost facilities of its kind in the world a facility that has a large range of capabilities with a wide range of materials. It is a perfect example of dual-use technology at work," Jones said, "and we have been made welcome which creates a strong technical attraction." 

Metallamics was one of the first small companies to enter into a user agreement with ORCMT. User facility agreements are reimbursable partnerships with provisions for subsidization for small business and educational partnerships. 

Today there are 28 user agreements, seven of those with small business, 16 with educational institutions and four with large businesses. 
 
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