Development of a composite suitable for rapid prototype machining

In an attempt to reduce product development time, many rapid prototyping techniques are being developed. Such techniques are effectively in response to various demands of the consumer. In particular, high-speed machining is superior to SLA, SLS, LOM, and FDM in cases in which the product does not have a cavity. However, since work related to high-speed machining has been based only on existing materials, this has limits in adaptation to the various demands. To overcome this problem, a new composite suitable for rapid prototype machining is introduced in the present study. This composite is a particulate-reinforced composite which consists of aluminum powder for the particle and epoxy for the matrix. The mechanical properties and the machinability of the material are tested to verify the suitability of this composite for high-speed machining. In particular, as an example of the application, prototypic molds are machined with high-speed machining and then used for the injection molds of a fan.