1 Copyright © 2009 by ASME Proceedings of the 2009 ASME International Manufacturing Science and Engineering Conference MSEC2009 October 4-7, 2009, West Lafayette, Indiana, USA MSEC2009-84361 Requirements Selection for Rapid Prototyping: Polyphenylsulfone as a Mold Material for Spin Casting Polyurethane Resin Thomas Martens Clemson University – International Center for Automotive Research Greenville, S.C , USA Laine Mears Clemson University – International Center for Automotive Research Greenville, S.C , USA Mike Dotson Michelin Americas R&D Company Greenville, S.C , USA Phillip Sanger Western Carolina University Cullowhee, N.C , USA Monty Graham Western Carolina University Cullowhee, N.C , USA ABSTRACT For the development of a rotational symmetrical polyurethane part with a steel reinforcement, a requirement/constraint driven approach to process design has been taken. In this approach a scale model of the process was built using fused deposition modeling (FDM) rapid prototyping technique, then used to validate design, material and process parameters. After selection and testing on the scaled prototype, results were used to define a full-sized spin casting mold built using Polyphenylsulfone (PPSF). Keywords: Constraint driven design, PPSF, Spin Casting, PUR, Rapid Tooling 1.0 INTRODUCTION The development of a new part design can be expensive and time consuming. To lower the up-front costs, and reduce time to testing, rapid prototyping offers an alternative to produce tooling for validation activities. In this way, part and design features can be tested and evaluated long before the part will be mass manufactured. However, care must be taken with respect to process requirements when selecting the material and process parameters, and the expected effect on part characteristics. In this paper, an approach is described, where this evaluation step is divided into two parts: first a scale- model prototype process and part is built, the results of which feed into process selection and design for the full-size part. The purpose of creating a scale model is to gather data which is then used in the design of the full-size part process. The approach of building a scale model also opens the possibility to do iteration steps. A second or third scale model could be built during design and process improvements without exceeding the cost of a full scale part. 2.0 BACKGROUND Rapid prototyping as a manufacturing technology for prototype design testing is a relatively mature process. More recently, tooling for alternative processes such as casting and injection molding has been prototyped for production testing, but this application has been limited by the material properties of conventional rapid prototyping materials. In this section, we present pertinent research on use of rapid prototyping, and in particular the selected PPSF material, as a process validation and testing activity. DRAFT