RAMPF I Tooling Solutions

Transcription

1 RAMPF I Tooling Solutions US

2 Innovative solutions for model, mold, and tool making RAMPF Group RAMPF Tooling Solutions The international RAMPF Group stands for engineering and chemical solutions and caters to the economic and ecological needs of industry. The company based in Grafenberg (near Stuttgart), Germany, is the world s largest producer of high-performance, high-quality styling, modeling, and working board materials. Our range of competencies includes: > Production and recycling of materials for modeling, lightweight construction, bonding, and protection > Technical production systems for precise, dynamic positioning and automation, as well as technologies for complex composite parts production > A comprehensive range of solutions and services, particularly for innovative and customer-specifi c requirements Services and products such as Close Contour Pastes, Close Contour Casting, including large-volume casting, 1 : 1 casting, and Close Contour Blocks ensure the manufacture of outstanding Close Contour models and molds. The company develops pioneering systems for the composites industry that cover a wide variety of production processes and a broad range of temperatures. This know-how helps our customers achieve profi table and sustainable growth. Trusting relationships are of utmost importance to RAMPF. They are a vital part of the family-owned company s success story which now spans over 35 years. The very latest production processes and facilities, combined with expert advice and customer-specifi c service, ensure that our products are manufactured cost effectively and environmentally friendly, and conform to the highest quality standard worldwide. RAMPF thinks globally and acts locally. The company has production facilities strategically located in Germany, the United States, Canada, China, and Japan. Machine Systems Production Systems Composite Solutions Eco Solutions Polymer Solutions Tooling Solutions

3 Range of products and services 01 I Materials Creative, high-performance, sustainable: RAMPF Tooling Solutions develops and produces styling, modeling, and working board materials, Close Contour Pastes, Close Contour Blocks, Close Contour Castings, and liquid systems. Supply-chain management Production Close Contour Casting services Research and development Prototyping RAKU TOOL Close Contour Pastes Polyurethane and epoxy liquid systems RAKU TOOL Tooling Solutions Tooldesign and construction Recycling Technicalsupport and applications technology Modelmaking RAKU Board materials TOOL RAKU TOOL Close Contour Casting Mold design and construction Paste application 02 I Production systems Customized, high-tech, professional: RAMPF Tooling Solutions develops systems for use throughout the entire production chain from prototyping, model, mold, and tool construction to production for existing and future customers and market requirements. Internaland externaltraining 03 I Services Customer-oriented, skilled, committed: The experts from RAMPF Tooling Solutions support their customers in techno logy and product applications, and in the implementation of their ideas including on-site when necessary. They also offer training courses in which the products and solutions are presented using prac tical demonstrations.» We provide our customers and partners with customized tooling solutions for cost- effective and high-quality model, mold, and tool construction. We work with them to develop creative, customized solutions adapted to their specific needs. Expert advice, customer-specific service, and rapid technical support are all standard at RAMPF. «02I03

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5 RAKU TOOL l Board materials We find solutions for your applications For more than 35 years RAMPF Tooling has been producing board materials. We are the market leader with the world s largest production of styling, modeling, and working boards. > High-performance range of standard products which can be adapted to meet changing market needs. > Complete package solution comprising boards, matching adhesives, and repair pastes. Your benefits > Quick and individual modification and customization of existing products > Comprehensive technical support > Made in Germany > High quality and stringent quality control Area Key Applications Key Properties Density g/cm³ Styling Design Modelling Prototyping / Small series Foundry > Program proving > Supporting structures > Design studies > Negative molds > Cubing > Show cars > Data control models > Functional Cubing > Lay-up tools > Jigs & Fixtures > Hammer forms > Lay-up tools > Rapid prototyping casting molds > Flanging tools > Welding fixtures > Pattern plates > Core boxes > Models > Negatives > Auxiliary tools > Fine surface > Easy to process > Dimensionally stable > Very fine surface > Easy to machine > Dimensionally stable > Eco-friendly > Good mechanical properties > Easy to machine > Impact and edge strength > Excellent abrasion resistance > Good temperature resistance > Low thermal expansion > Eco-friendly and sustainable Ceramics > Models > Appliance and working models > Negatives > Auxiliary tools > Excellent surface > Excellent styrene resistance Composites > Models > Lay-up molds > Prepreg lay-up tools > Good impact strength > Chemical resistant > Can be polished to a high gloss ( Density) 04I05

6 RAKU TOOL Boards RAKU TOOL SB-0064 RAKU TOOL SB-0096 RAKU TOOL SB-0130 RAKU TOOL SB-0160 Styling and Design with RAKU TOOL Color beige aqua light yellow light gray Density (ISO 1183) g/cm 3 lb/ft 3 (ca.) Applications > Design studies > CNC program checking > Supporting structures for tooling pastes > Negative mold for casting > Design studies > CNC program checking > Supporting structures for tooling pastes > Negative mold for casting > Design studies > CNC program checking > Supporting structures for tooling pastes > Negative mold for casting > Styling & design models > Data control models > Supporting structures for Close Contour Paste Key Properties > Very light weight with good surface > Easily shaped > Good heat resistance > Resistant to organic solvents > Very light weight with good surface > Easily shaped > Good heat resistance > Resistant to organic solvents > Very light weight with good surface > Easily shaped > Good heat resistance > Resistant to organic solvents > Light weight and smooth surface > Easily shaped, low dust > Resistant to organic solvents Hardness (ISO 868) Shore D Coefficient of thermal expansion (ISO 11359) 10-6 K -1 in/in/ 0 Fx Deflection temperature (ISO 75) C F Compressive strength (ISO 604) MPa psi Flexural strength (ISO 178) MPa psi Dimensions mm in 2 x 24 x 96 4 x 24 x 96 6 x 24 x 96 8 x 24 x 96 2 x 48 x 96 4 x 48 x 96 6 x 48 x 96 8 x 48 x 96 Other thicknesses are available. 2 x 24 x 96 4 x 24 x 96 6 x 24 x 96 8 x 24 x 96 2 x 48 x 96 4 x 48 x 96 6 x 48 x 96 8 x 48 x 96 Other thicknesses are available. 2 x 24 x 96 4 x 24 x 96 6 x 24 x 96 8 x 24 x 96 2 x 48 x 96 4 x 48 x 96 6 x 48 x 96 8 x 48 x 96 Other thicknesses are available. 2 x 24 x 96 4 x 24 x 96 6 x 24 x 96 8 x 24 x 96 2 x 48 x 96 4 x 48 x 96 6 x 48 x 96 8 x 48 x 96 Other thicknesses are available. Bonding with RAKU TOOL > PE-3804 > PF-3708/ PH-3978 > PE-3804 > PF-3708/ PH-3978 > PE-3804 > PF-3708/ PH-3978 > PE-3804 > PF-3708/ PH-3978 Mixing ratio (pbw) 1 part 100 : part 100 : part 100 : part 100 : 100 Color beige beige beige beige beige beige beige beige Pot life (min.) Minimum curing time (h) Repair with RAKU TOOL Repair with adhesive bonded inserts Repair with adhesive bonded inserts Repair with adhesive bonded inserts Repair with adhesive bonded inserts SB = Styling Board l MB = Modeling Board l WB = Working Board. Special sizes available on request.

7 /8US. Errors excepted. Subject to change. RAKU TOOL Boards RAKU TOOL SB-0240 RAKU TOOL SB-0320 RAKU TOOL SB-0470 RAKU TOOL SB-0497 Styling and Design with RAKU TOOL Color light green apricot apricot brown Density (ISO 1183) g/cm 3 lb/ft 3 (ca.) Applications > Styling & design models > Data control models > Styling & design models > Data control models > Styling & master models > Styling models > Master models > Data control models Key Properties > Good surface structure > Easily shaped and machined > Resistant to organic solvents > Very good surface structure > Easily shaped and machined > Very good surface structure > Easily machined > Very fine and smooth surface structure > Easily machined > Low coefficient of thermal expansion Hardness (ISO 868) Shore D Coefficient of thermal expansion (ISO 11359) 10-6 K -1 in/in/ 0 Fx Deflection temperature (ISO 75) C F Compressive strength (ISO 604) MPa psi , ,500 2, ,700 2,300 Flexural strength (ISO 178) MPa psi , ,500 2, ,500 2,800 Dimensions mm in 2 x 24 x 96 4 x 24 x 96 6 x 24 x 96 8 x 24 x 96 2 x 48 x 96 4 x 48 x 96 6 x 48 x 96 8 x 48 x 96 Other thicknesses are available. 2 x 24 x 96 4 x 24 x 96 6 x 24 x 96 8 x 24 x 96 2 x 48 x 96 4 x 48 x 96 6 x 48 x 96 8 x 48 x x 500 x x 19.7 x x 500 x x 19.7 x x 500 x x 19.7 x x 500 x x 19.7 x x 48 x 96 4 x 48 x 96 6 x 48 x 96 Bonding with RAKU TOOL > EP-2305/EH > EP-2305/EH > EP-2305/EH > EP-2306/EH Mixing ratio (pbw) 100 : : : : 30 Color apricot apricot apricot brown Pot life (min.) Minimum curing time (h) Repair with RAKU TOOL Repair with adhesive bonded inserts Repair with adhesive bonded inserts Repair with adhesive bonded inserts Repair with adhesive bonded inserts SB = Styling Board l MB = Modeling Board l WB = Working Board. Special sizes available on request. RAMPF Group, Inc Wixom Tech Drive l Wixom, MI 48393, USA T l F E info@rampf-group.com

8 RAKU TOOL Boards RAKU TOOL MB-0600 RAKU TOOL MB-0670 RAKU TOOL MB-0720 RAKU TOOL WB-0691 Modeling with RAKU TOOL Tool Making with RAKU TOOL Color brown brown brown light blue Density (ISO 1183) g/cm 3 lb/ft 3 (ca.) Applications > Master & cubing models > Patterns > Master & cubing models > Patterns > Master & cubing models > Patterns > Lay-up tools for low temperature tooling prepregs, vacuum forming molds, medium temperature applications Key Properties > Fine surface structure > Fine surface structure > Excellent surface structure > Very fine surface structure > Easily shaped and machined > Easily shaped and machined > Low coefficient of thermal expansion > Excellent machinability > Low coefficient of thermal expansion > Low coefficient of thermal expansion > Good compressive and flexural > Heat resistant up to 90 C strength Hardness (ISO 868) Shore D Coefficient of thermal expansion (ISO 11359) 10-6 K -1 in/in/ 0 Fx I Deflection temperature (ISO 75) C F I Compressive strength (ISO 604) MPa psi I 2,200 2, ,200 2, ,900 3, ,300 8,700 Flexural strength (ISO 178) MPa psi I 2,200 2, ,900 3, ,600 4, ,600 5,100 Dimensions mm in 25 x 500 x x 19.7 x x 500 x x 19.7 x x 500 x x 19.7 x x 500 x x 19.7 x x 500 x x 19.7 x x 500 x x 19.7 x x 500 x x 19.7 x x 500 x x 19.7 x x 500 x x 19.7 x x 500 x x 19.7 x x 500 x x 19.7 x x 500 x x 19.7 x x 500 x x 19.7 x x 500 x x 19.7 x x 500 x x 19.7 x x 500 x x 19.7 x x 500 x x 19.7 x x 500 x x 19.7 x x 500 x x 19.7 x x 500 x x 19.7 x x 610 x x 24.0 x x 610 x x 24.0 x x 610 x x 24.0 x x 610 x x 24.0 x x 610 x x 24.0 x 60.0 Bonding with RAKU TOOL > EP-2306/EH > EP-2306/EH > EP-2306/EH > EP-2303/EH Mixing ratio (pbw) 100 : : : : 20 Color brown brown brown light blue Pot life (min.) Minimum curing time (h) Repair with RAKU TOOL Repair with adhesive bonded inserts Repair with adhesive bonded inserts Repair with adhesive bonded inserts Repair with adhesive bonded inserts SB = Styling Board l MB = Modeling Board l WB = Working Board. Special sizes available on request. eco-friendly eco-friendly eco-friendly

9 /8US/Page 2. Errors excepted. Subject to change. RAKU TOOL Boards RAKU TOOL WB-0700 RAKU TOOL WB-0801 RAKU TOOL WB-1223 RAKU TOOL WB-1700 Tool Making with RAKU TOOL Color light green gray red dark gray Density (ISO 1183) g/cm 3 lb/ft 3 (ca.) Applications > Lay up tools for pre-preg > High temperature applications > Vacuum forming molds > Master models > Cubing models > Tooling jigs and fixtures > Vacuum forming tools > Foundry pattern plates > Hammer tools > Checking fixtures for metal parts > Metal forming tools > Vacuum forming molds, jigs > Foam molds, rapid prototyping molds Key Properties > Very fine surface structure > Very easily machined > Temperature resistance up to 130 C > Fine surface structure > High HDT and very low CTE > Good compressive and flexural strength > Low wear of milling tools > Resistant to amine > Most proven working board on the foundry market > Resistant to dry ice cleaning > Good abrasion resistance > Very dense surface structure, can be polished > Easily machined > Good temperature resistance > Excellent compressive strength > High abrasion resistance Hardness (ISO 868) Shore D Coefficient of thermal expansion (ISO 11359) 10-6 K -1 in/in/ 0 Fx Deflection temperature (ISO 75) C F Compressive strength (ISO 604) MPa psi ,300 8, ,800 6, ,700 10, ,000 19,000 Flexural strength (ISO 178) MPa psi ,400 5, ,100 5, ,000 12, ,000 12,000 Dimensions mm in 50 x 500 x x 19.7 x x 500 x x 19.7 x x 500 x x 19.7 x x 500 x x 19.7 x x 500 x x 19.7 x x 500 x x 19.7 x x 500 x x 19.7 x x 500 x x 19.7 x x 500 x x 19.7 x x 20 x 40 2 x 24 x 60 3 x 24 x 60 4 x 24 x x 500 x x 19.7 x x 500 x x 19.7 x 29.5 Bonding with RAKU TOOL > EP-2304/EH > EL-2210/EH * > EL-2210/EH * > EL-2210/EH * Mixing ratio (pbw) 100 : : : : 60 Color light green transparent transparent transparent Pot life (min.) Minimum curing time (h) Repair with RAKU TOOL Repair with adhesive bonded inserts Repair with adhesive bonded inserts Repair with adhesive bonded inserts Repair with adhesive bonded inserts SB = Styling Board l MB = Modeling Board l WB = Working Board. * Different mix ratios for special mixtures see technical data sheet. RAMPF Group, Inc Wixom Tech Drive l Wixom, MI 48393, USA T l F E info@rampf-group.com eco-friendly

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11 RAKU TOOL l Close Contour products Every job is different. So are our solutions. Close Contour Pastes, Close Contour Blocks, and Close Contour Castings are high-performance products and the result of targeted development work and years of practical experience. We tailor our Close Contour products to your specific requirements quickly and effectively. Close Contour Pastes The paste is applied to a close contour shape supporting structure, cured and then machined according to CAD data. RAMPF Tooling Solutions also offers a Close Contour Paste application service. Your benefits > Close Contour shape > Rapid milling > Little waste > Seamless, fine surface Close Contour Blocks Special blocks are produced in well-known board quality according to customer specifications (L W H) and supplied as customized, rectangular, unmachined blocks. Close Contour Castings Close Contour Castings are supplied as a three-dimensional shape which is already a close contour of the final shape. The production process takes place in-house at RAMPF Tooling Solutions. A light close contour mold (e. g. EPS or RAKU TOOL SB-0080) is machined using the area-based data supplied by the customer. A release agent is applied and the mold filled using a special casting process. Demolding and post curing of the casting is next, followed by machining. Very close co-operation between the customer and RAMPF is essential during this process. 06I07

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13 RAKU TOOL l Close Contour products at a glance Close Contour Pastes Close Contour Blocks Close Contour Castings Key Applications Design and styling Master models, cubing models Molds Jigs and Fixtures Tools Foundry patterns Qualitative selection criteria Size of the models / tools Medium to very large* Small to medium Medium to large* Mechanical properties dependent on product See data sheet See data sheet See data sheet Economic selection criteria Marginal waste Quick machining as close contour shape Light, cost-effective supporting structures No handling of liquid products Delivery time Immediate Approx. 5 days Approx. 10 days Equipment costs None None Work hygiene / exposure marginal None None Specifics Seamless surface Seamless surface Seamless surface * With large models / molds build-up in segments possible 08I09

14 /10US. Errors excepted. Subject to change. RAKU TOOL Close Contour Products Resin Hardener Mix ratio (pbw) Color Pot life 25 C (min) Layer thickness (mm) Density g/cm 3 (ISO 1183) ca. Key Properties Applications RAKU TOOL Close Contour Pastes (machine applied) 1000 ml CP-6070 CP : 100 brown Very smooth, homogeneous surface, easy to machine, very little dust, can be machined after 14 h RT curing Design and styling models, master models, molds CP CP : 100 light blue Easy to machine, low dust, very fine and homogeneous surface, high surface hardness and low CTE, can be machined after 14 h RT curing Jigs and checking fixtures, data control models, tools, molds for direct tooling RAKU TOOL Repair Systems for Epoxy Close Contour Pastes 100 ml CP-6070 EH : 50 brown > Slump resistant on vertical surfaces in layers up to 20 mm thickness > Sufficient pot life with rapid curing > Similar mechanical properties to those of cured Close Contour Pastes Repair of Close Contour Paste CP-6070 R/H RAKU TOOL Epoxy Hand Pastes 500 ml EP-2342 EH : 100 apricot Easily shaped with wood working tools, good adhesion to most supporting structures Styling and Design models, master models EP-2301 EH : 100 brown Easily shaped with wood working tools, good adhesion to most supporting structures Styling and Design models, master models, patterns RAKU TOOL Close Contour Casting (CCC*) / Close Contour Blocks (CB*) Color Density Shore Coefficient of Deflection Compressive Compressive Key Properties Applications g/cm 3 Hardness D thermal expansion temperature strength MPa modulus MPa (ISO 1183) (ISO 868) 10-6 K -1 (ISO 11359) C (ISO 75) (ISO 604) (ISO 604) CC-6010 / CB-6010 brown > Fine surface structure > Easily machined > Similar properties to RAKU TOOL modeling boards Master models, cubing models, patterns CC-6503 / CB-6503 blue > Very dense structure > Very homogeneous, fine surface and as a result, very good surface of nickel bowl, i.e. little finishing required and therefore large cost savings > Easily machined like board material WB-1700 > Low coefficient of thermal expansion > Good abrasion resistance Galvanobath models, lay up tools, vacuum trim fixtures, stretch form dies, RIM tools CC-6506 / CB-6506 dark gray > Very dense surface structure > Can be polished > Good heat resistance > High compressive strength > Good resistance to chemicals > Time savings through direct milling of mold via surface data > Better pressing of sheet metal parts Molds for ceramic pressure casting, metal stamping, vacuum forming tools, lay up tools, prepreg tools *CC Close Contour Casting is supplied as a three dimensional shape which is already a close contour of your final shape. *CB Close Contour Block is supplied as a customized size of a rectangular, unmachined block. *CP Close Contour Paste (R= Resin, H= Hardener) CB: The general rule is that RAMPF Tooling only adds an offset for shrinkage to the dimensions indicated on the customer s order. The customer has to assess how many mm machining/processing offset is needed for the unmachined block he receives. We recommend a machining/processing offset of 10 mm. Dimensions ordered = dimensions supplied, within the specifications. Close Contour Blocks are unmachined, only basic cleaned cast blocks. Some release agent residue on the surface is possible. Sharp edges are milled due to risk of injury. CC: For a dimensions of up to 1000 mm, an offset of 20 mm per surface to be worked on must be added. All larger dimensions need to have a shrinkage offset of % (dependent on product) + offset for processing of minimum + 10 mm per surface. However, each project still needs to be discussed with the responsible project manager at RAMPF Tooling. RAMPF Group, Inc Wixom Tech Drive l Wixom, Mi 48393, USA T l F E info@rampf-group.com

15 01 Applications Further Information Image 1: Interior cubing of passenger cabin: Board material RAKU TOOL MB Advantages: > Accurate, dimensionally stable > Finest details can be reproduced > 5.9 in and 7.9 in thicknesses > Adhesive s hardness and color matched to the board material Image 2: Fixture Board material RAKU TOOL WB Advantages: > 75 % weight saving compared with metal > More cost-effective than metal > Easy processing and post-processing (ensuring separation of board material and emulsion) > Any required dimension can quickly be joined by bonding the board material. No welding or drilling required. The final properties remain the same. Image 3: Design model Board material RAKU TOOL MB-0600 Advantages: > Excellent surface structure > Accurate, dimensionally stable > Finest details can be reproduced > Easily shaped and machined > Adhesive s hardness and color matched to the board material 3

16 Further Information Image 4: Production of a UAV master model with RAKU TOOL WB-1405 Advantages: > Easy to machine > Excellent surface 4 Image 5: Production of a car model with RAKU TOOL CP-6070 / CP-6072 Advantages: > Little finishing required due to fine, seamless surface structure > Easy to machine > Specially suitable for large model 5 Image 6: Production of a prepreg lay-up tool made with RAKU TOOL CC-6503 for the manufacture of an airplane acoustic panel. Advantages: > Excellent surface of prepreg lay-up tool > Temperature resistant up to 80 C > Compatible with all paints 6 10I11

17 RAMPF Group I Locations DE I Bessenbach, RAMPF Precision Grinding DE I Pirmasens, RAMPF Eco Solutions DE I Grafenberg, RAMPF Holding DE I Grafenberg, RAMPF Polymer Solutions DE I Grafenberg, RAMPF Tooling Solutions CA I Burlington, ON, RAMPF Composite Solutions, Inc. DE I Wangen, RAMPF Machine Systems DE I Zimmern o. R., RAMPF Production Systems US I Wixom, MI, RAMPF Group, Inc. US I St. Johns, MI, RAMPF Group, Inc. US I Suwanee, GA, RAMPF Group, Inc. JP I Osaka, RAMPF Group Japan K.K. CN I Taicang, RAMPF (Taicang) Co., Ltd. RAMPF Holding GmbH & Co. KG Albstrasse Grafenberg, Germany T E info@rampf-gruppe.de RAMPF Machine Systems GmbH & Co. KG Daimlerstrasse Wangen bei Göppingen, Germany T E machine.systems@rampf-gruppe.de RAMPF Production Systems GmbH & Co. KG Römerallee Zimmern o. R., Germany T E production.systems@rampf-gruppe.de RAMPF Composite Solutions, Inc John Lucas Drive Burlington, Ontario L7L 6A6, Canada T E composite.solutions@rampf-group.com RAMPF Eco Solutions GmbH & Co. KG Elsässer Strasse Pirmasens, Germany T E eco.solutions@rampf-gruppe.de RAMPF Polymer Solutions GmbH & Co. KG Robert-Bosch-Strasse Grafenberg, Germany T E polymer.solutions@rampf-gruppe.de /4US RAMPF Tooling Solutions GmbH & Co. KG Robert-Bosch-Strasse Grafenberg, Germany T E tooling.solutions@rampf-gruppe.de RAMPF Group, Inc. RAMPF Group Japan K.K. Oriental Shin-Osaka Building 2F Nishinakajima , Yodogawa-ku, Osaka, Japan T E info@rampf-group.jp RAMPF (Taicang) Co., Ltd. Taicang Economy Development Area No. 8 North Lou Jiang Road, Taicang , Jiangsu Province P.R. China T E info@rampf-group.com.cn Wixom Tech Drive l Wixom MI USA T E info@rampf-group.com