Laser sintered rapid tools with improved surface finish and strength using plating technology

Rapid tooling (RT) is a technology that can contribute greatly in reducing product development cycle. However, currently used RT methods permit smaller, pre-serial production runs to be conducted economically only in a limited number of cases. To make this technology viable for all cases, the quality of the rapid tools should be improved in order to be as close as that obtained in the case of traditional mould. In this regard, direct metal laser sintering (DMLS) technique shows great promise. But the common limitations of the rapid tools produced by DMLS technique are low surface finish, low wear resistance, soft and porous. A comprehensive investigation has been conducted to improve the quality of the RT produced by DMLS technique to an industrial acceptance level. Electroless nickel (EN) plating and semi-bright nickel electroplating have been chosen for their unique characteristics while they are applied either alone or combined with each other to achieve the best possible results. The investigated results demonstrate that the applied techniques possess enormous potential in developing rapid tools.