The Keltool process is an advanced process
of producing long-life soft tooling quickly
and economically for prototype and production
runs from one to hundreds to even millions
of plastic injection molded parts.
The word "Keltool"
refers to the proprietary powder metal sintering
process, which involves infiltrating a fused
metal part with copper alloy. This alloy
fills in the voids in the otherwise porous
material, producing a surface with the finish
and hardness necessary for an injection
This process requires a
master pattern, typically an ACES SLA model,
that can be used to develop a silicone mold
that will then be used to produce the Keltool
mold. The Keltool mold is then processed
with a copper infiltration and sintered
to increase its strength and cure the mold.
The finished Keltool part has the hardness
of a A6 Tool Steel and can be machined like
a traditional hard tool.
- Production Time:
- Utilizing the 3D Keltool
process, mold inserts can be turned around
in two weeks time. Inserts can be fit
into a mold base and can be producing
injection molded plastic parts in just
The process develops
- 1-2 Days: Working
- 1-2 Days: Development
of core and cavity inserts.
- 2 weeks: A6 tool
steel mold inserts.
- 2-3 days: fitting
of inserts into a mold base.
- 2-3 days: molded
plastic parts in a specific resin.
- Tool Life Expectancies:
- 100,000 to 10,000,000
shots depending on material.
- The accuracy of Keltool
is a function of the master pattern incorporating
the appropriate shrinkages for the pattern
itself, the silicone mold, Keltool process,
and the thermoplastic material.
Accuracies are typically 0.005 to 0.015
- Size Limitations
- The Keltool part (mold)
is limited to 6 inches in all directions.
Therefore, any parts produced would be
limited to about 4 inches in all directions.