Rapid Prototyping Journal

Purpose – The purpose of this paper is to propose a method to obtain hybrid rapid tools with elementary component assembly.

Design/methodology/approach – The authors' method proposes a functional representational model, starting with the product features, analyzed from three points of view: a feasibility analysis; a manufacturing analysis; and an assembly and synthesis analysis. This method, based on CAD STEP AP-224 data, makes it possible to obtain an exhaustive list of solutions for the module. The work is illustrated with an industrial example. To construct the Assembly Identity Card (AIC) and test the various parameters that influence the quality of the injected parts, a hybrid injection mold has been produced. The methodology associated with the use of this AIC uses a “representation graph”, which makes it possible to propose a set of valid solutions for assembling the various tooling modules. This method is validated by industrial example.

Findings – The product part is decomposed into a multi-component prototype (MCP), instead of being made as a single part, which optimizes the manufacturing process and enables greater reactivity during the development of the product.

Research limitations/implications – The final goal is to propose a software assistant used in association with CAD system during the design of hybrid rapid tooling. An important work concerning the features recognition must be implemented. The assembly of the different parts of the hybrid rapid tooling must be considered and optimized.

Practical implications – This method allows the selection of the best process technologies from manufacturing tools.

Originality/value – The analysis of manufacturing hybrid rapid tooling has not been studied previously.