Trim Tool Case Study

Complex surface geometries can mandate expensive and time consuming tooling solutions. Traditional solutions include CNC machining and composite tooling. Machined tooling is a trade space between raw material costs and CNC capacity. Offloading tooling work from heavily burdened CNC’s can open up capacity for higher value products. Composite tooling requires a series of pattern tools and back up structures(plywood crates or welded tubular frames) that can induce a variety of challenges. These processes can result in increased expenses, long lead times, consume valuable resources (CNC machine time), and families of patterns that need to be tracked and maintained in addition to the tools themselves. 

Additive manufacturing enables users to create complex geometries from a variety of tough thermal polymers. Solid models are used to fabricate complex geometries directly, without the need for any secondary patterns. Often, the design rules for optimized additive manufactured tooling can be leveraged to provide ergonomic fixtures that simplify part processing and employ lower cost manufacturing solutions. 


Fiberglass Splash Tool

• CAD/Reverse Engineer.
• Produce pattern for fiberglass layup
  (CNC, splash or Egg Crate).
• Support frame fab.
• Fiberglass layup and frame integration.
• Finish tool (edge clean up].







Fiberglass Splash Tool


Cosine Manufactured Tool 

Ready to Print
• Up to 1 lb/hour Material Deposition Rate.
• $8.40/hour Machine Utilization Cost                (5yr amortization). 
• $0.60/hour Electrical Cost.


Material Cost (choose one):
• $1/hour Base Polymer Pellet Material Cost.
• $8/hour Base/Neat Filamentized
  Material Cost.
• $33/hour Filled Filamentized Polymer               Material Cost.



Manufacturing Method Comparison

Cosine Machine Utilization Cost to Owners

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