The Dualform process enables accurate replication of existing panels or hand-crafted, fabricated panels. The panels are submerged in a liquid alloy; the heating is then turned off, and the alloy is allowed to cool, forming the top and bottom dies.
The original sample is then removed, and the mould surfaces are hand-dressed. The press is then ready to operate.
Dualform is a patented process incorporating a special double-acting hydraulic press. This process enables the simultaneous manufacture of matched top and bottom dies within the press.
This, in turn, can be used for:
- The manufacture of finished pressed panels
Dualform tools are cast using a unique, low-melting-point alloy called 'Lowmelt', housed in a special fabricated flask situated within the press tool space. After use, the tools are melted down in situ, and new tools are cast.
The process can be completed in approximately three hours on smaller presses and under 24 hours on the larger Dualform models.
- More than 250 Dualform presses have been sold worldwide
Repeatable process
The operation can easily be repeated for each new (or repeat) batch of pressed components.
Significant cost savings
The Dualform process enables the manufacturer to make significant savings both in production and in tooling costs.
From the creation of matched top and bottom dies to the production of finished components, the Dualform process provides the manufacturer with total production flexibility and a dramatically reduced time-to-market for new products and designs.
Benefits
- Minimal tooling costs
- Quick tool manufacture ensures that Dualform is an extremely cost-effective method of prototype engineering and low-volume production
Applications
- Prototypes
- Car-body panels
- General aircraft panels
- Short-run pressings
