This paper describes a rapid tooling process that integrates solid freeform fabrication (SFF) with electroforming to produce metal tools including molds, dies, and electrical discharge machining (EDM) electrodes. Based on experimental data analysis, the geometry and material of the SFF part, the properties of the electroformed metal, and the process parameters are significant factors that cause inaccuracy in the manufactured tools. Thermomechanical modeling and numerical simulation is used to determine the geometry of the SFF part and the electroform thickness for minimizing the manufacturing time and cost while satisfying the tooling accuracy requirement.

Meeting Name

10th Annual Solid Freeform Fabrication Symposium (1999. Aug. 9-11, Austin, TX)


Mechanical and Aerospace Engineering


This work is partially supported by the New Jersey Commission on Science and Technology via the Multi-lifecycle Engineering Research Center at New Jersey Institute of Technology.

Keywords and Phrases

Solid freeform fabrication; Rapid tooling; Electroforming; Mold; EDM electrode; Finite element analysis

Document Type

Article - Conference proceedings

Document Version

Final Version

File Type




Publication Date

11 Aug 1999

Included in

Manufacturing Commons