Labels: Metal Prototypes, Quick Cast patterns, rapid prototyping, RTV Molding, SLA prototype, stereolithography

ProtoCAM has done extensive work with prototypes for medical applications. A recent medical rapid prototyping project involved an orthopedic prototype for knee replacement. Previous knee replacement orthopedic prototypes had been created using ThermoJet printer, then later using laser sintering (SLS) and CastForm or DuraForm PS material.

In this case, ProtoCAM found a new use for an existing technology. Instead of using SLS, the knee replacement prototype was created by casting it using a stereolithography pattern and founder’s wax. While this is a less sophisticated and older technology, for this application it was a very good fit. The finish on the SLA pattern was very precise and detailed. The benefits to the customer were that the detailed finish was brought forward into the wax prototype that was later used in the investment casting process. Also, the cost of this prototyping process was lower.

Using this rapid prototyping process, the customer was able to identify areas of differential shrink in the final metal casting. That information was then used for the final metal molds that produced the production wax patterns.

ProtoCAM’s innovative use of an established technology helped streamline the rapid prototyping and product development process. For the customer, this cut their time to market by almost 1 year.

ProtoCAM has a very strong practice in many different types of medical rapid prototyping, as this knee replacement prototype demonstrates. ProtoCAM has done work in:

• Medical Device Rapid Prototyping
• Medical Stereolithography
• Rapid Prototype Physical Anatomical Parts
• Medical Model Prototypes

Labels: Medical Rapid Prototypes, Metal Prototypes, rapid prototyping

ProtoCAM offers the ability to produce parts in A6 tool steel using the selective laser sintering (SLS) process and LaserForm™ A6 steel material. Using LaserForm™ A6 offers our customers an alternative to traditional manufacturing techniques such as sand casting, plaster casting or investment casting. The metal parts produced using SLS and LaserForm™ A6 can be polished, welded, plated and machined. Parts must fit approximately within a 12”x10” envelope with the maximum height being between 6” to 7”. Additionally, all part features must be greater than .040”. The “as sintered” hardness of the part is 10-20 Rockwell “C” but can be heat treated to 39 HRc.

The SLS with LaserForm™ A6 process starts by selective laser sintering a blend of A6 tool steel, tungsten carbide and a binder. When finished, the “green” part is infiltrated with bronze yielding a fully dense part composed of approximately 60% A6 and 40% bronze. Using LaserForm™ material is the definitive solution for low volume rapidly produced metal prototypes, parts or tooling inserts for injection molding. Additionally, if your metal part application is not suitable for using LaserForm™, ProtoCAM offers investment casting, plaster casting and sand casting parts.


Please contact ProtoCAM with your application or any questions you might have about LaserForm™ A6, metal prototypes and metal parts.



LaserForm™ is a registered trademark of 3D Systems, Inc.

Labels: LaserForm, Metal Prototypes, Selective Laser Sintering