Cost and Lead-Time Implications of Robotic Patternmaking in the Manufacture of Body Press Tooling

The manufacture of polystyrene patterns and castings used for body press tooling represent a significant proportion of the tooling procurement costs. The combined use of 3D modelling and computer aided machining using an integrated multi-axis Robotic system has been shown to give benefits of reductions in both pattern lead time and manufacturing cost. Furthermore the production of a consistent cast tool profile and a reduced machine stock provide additional cost and time savings in the machineshop as well as an improved quality product. Case studies are discussed together with details of the developments undertaken to achieve the optimum tooling parameters for the machining of the polystyrene patterns.