To overcome these challenges, Xpress7 reached out to Westminster Tool because they knew Westminster Tool had Mantle’s metal 3D printer. Westminster Tool informed Xpress7 that this tool was ideal for Mantle’s technology because they could print all the features that would have traditionally required EDM.

Westminster Tool estimated that the thin, deep ribs would have required over 20 electrodes to be produced with sinker EDM. The design, programming, and production of the electrodes, combined with the long sinker EDM burning process, would have required a minimum of 180 hours. This long EDM process made the insert time-consuming and expensive to produce traditionally.

Instead, Westminster Tool printed the insert with its Mantle 3D printer and H13 tool steel. Mantle’s high precision shape refinement capabilities, including a 0.010” ball end mill, allowed for the thin deep ribs, blade start holes, and mold features to be printed.

In total, the insert required only a few hours of labor as the programming was automated and the machine ran “lights out” with no user interaction. Westminster Tool sent the part to Xpress7 for the final fitting, grinding of the parting line and a shutoff surface, wire EDM to the ejector pin holes, and polishing to achieve a draw polish. Xpress7 then assembled the mold.

By using a Mantle printed insert, Xpress7 saved 2 weeks off the production timeline. The time savings mainly came from being able to remove the 20+ electrodes and 180+ hours of sinker EDM required to build this insert traditionally.