Mechanical Reinforcement Applications

Coating RP models makes them more robust for handling or functional testing.  Below are several examples of how RePliForm’s customers use our coating to get more performance from their models.

	Pitney Bowes Reversing  Arm Assembly Uncoated SL models typically failed at 5% of the cycles needed for complete testing but there was concern about part tolerances if a coating was added.  High precision coated model was made by first displacing surfaces inward by 0.05 mm then applying 0.05 mm coating of copper + nickel.  Coated models withstood 400,000 cycles without failure.
Multiple Design Iterations The coated models to the right are two candidate designs for the same part. Uncoated SL models broke when thick envelopes went through the machine but the reinforcement provided by the coating allows part designs to be subjected to the complete range of testing without having to build prototype tooling.
Photo courtesy of Boeing Corp.	Boeing Aircraft Fairing Mock Up The coated SL models to the left are some of the biggest done in one piece by RePliForm. The larges parts are 1375 mm (54”) in length.  The customer needed to prevent sagging of the models when they were used in fit checking on an aircraft.  The coating performed so well that after the engineering checks were completed, the parts were used for marketing purposes and taken to customer locations to show off new hardware.
Cross Car Beam Mockup Sheet metal fabrication of a cross car beam was not fast or accurate enough to test component assembly and plastic RP models were not rigid enough on their own.  By coating RP models with 0.15 mm of copper + nickel, the customer was able to take advantage of the accuracy of the SLA and SLS models and provide enough rigidity to support a variety of instrument panel components..  This cross car beam mock up is more than 1500 mm in length, was coated in pieces and assembled (see photo upper right).  It was used confirm the fit of instrument panel components and helped identify more than 80 design issues.	Photos Courtesy of General Pattern
	Coated Medical Device The parts on the left are Objet models ~40 mm long.  They were built with working threads directly in the machine.  Application of 0.025 mm of copper + nickel dramatically increased the strength of the parts yet still permit the threads to function.

Sealing and Barrier Applications

Photo-cured SL resins are known to be sensitive to heat and      humidity.  A 0.05 mm thick metal coating allows even very thin walled parts to be used under water.  The barrier properties also allow SL models to be used in applications where out-gassing of the SL resin causes interference.

Electromagnetic Shielding Applications

Copper and nickel-plating on plastic parts is a common method used to control electromagnetic interference, radio frequency interference and static discharge problems with plastic components.  The thick (by normal plating standards) metal coatings RePliForm typically applies are more than up this task. Below is an application that takes advantage of the high electrical conductivity or our coatings.

Electroformed Coatings on 

Digital Sculptures