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232. The spray formed rapid tooling 

The spray formed rapid tooling may be used in plastic molds for injection molding parts. The spray formed rapid tooling may be used with mold slides. Currently, wear plates for spray formed rapid toolings are machined into the spray formed rapid tooling after the spray process is completed. Although the wear plates machined into the spray formed rapid tooling have worked well, they suffer from the disadvantage that the machining process is both laborious and time consuming. Another disadvantage is the thermal spray coatings are heavily oxidized and the wear plates can only be ground or electro discharge machined into the spray formed rapid tooling which is costly and another disadvantage is that the high oxide content does not allow for weld repair or traditional machining processes on the wear plates of the spray formed rapid tooling.

Accordingly, the present invention is a method of integrating wear plates into a spray formed rapid tooling. The method includes the steps of making a model of a desired tooling and constructing a ceramic pattern as the inverse of the model. The method also includes the steps of locating at least one wear plate on the ceramic pattern. The method further includes the steps of thermally spraying a metal material against the wear plate and ceramic pattern to form the desired tooling and embedding the wear plate into the desired tooling.

One advantage of the present invention is that a method is provided of integrating prefabricated cast or wrought wear plates into a spray formed rapid tooling at the same time the spray material is being deposited. Another advantage of the present invention is that the integration of wear plates in a spray formed rapid tooling shortens product development cycle time. Yet another advantage of the present invention is that the wear plate can be machined or modified after the spray formed deposit is completed.

Still another advantage of the present invention is that the wear plate can be conventionally machined to make it parallel to the surface of the slide. A further advantage of the present invention is that the wear plate can be conventionally machined instead of using the EDM process, thereby saving time and cost. Yet, a further advantage of the present invention is that the method eliminates secondary machining of the thermal spray material. Still a further advantage of the present invention is that the method reduces material loss. Another advantage of the present invention is that the method improves yield, quality and repeatability.

Once the spray formed rapid tooling is formed, the ceramic pattern is removed by chipping, grit blasting, or using a water jet. The slide contact surface can be machined "true" to the rest of the spray formed rapid tooling after the spray process is complete if the wear plate 16 was not in the exact location during the spray deposition.