Washout Tooling

Eliminates the expense and long lead time associated with manufacturing multi-piece metal breakdown tooling.

Washout Tooling is commonly used to create one piece composite parts featuring trapped geometries, such as bottles, aircraft ducting, pressure tanks, struts, and mandrels. ExOne® Washout Tooling eliminates the expense and long lead time associated with manufacturing multi-piece metal breakdown tooling. It also eliminates the need for multi-piece molds that are used to make castable washout tooling media. ExOne® Washout Tooling is significantly faster than competing 3D Printed soluble tooling technology. 

Proprietary binder and coating

The ExOne® binder system has been formulated to be water soluble up to 350°F, which allows for high temperature curing of many composite materials. The printing media available are silica and ceramic sand. After printing, a sealant coating is applied to the surface of the tooling to prevent resin migration into the tool from the composite part. Coating options include a spray-on coating system based on the binder chemistry, which is also water soluble, or a Teflon® tape wrap. When the composite lay-up is completed and cured, tap water is applied to the mandrel ends to begin the washout process. Washout is completed in a matter of minutes and leaves no residual material behind.


Specifications

Material Properties  ExOne®  Washout Tooling
Silica Sand Ceramic Sand
 Density 90 lb/ft3
95 lb/ft3
Maximum Use Temperature  350°F  350°F
 Coefficient of Thermal Expansion (RT-350°F)  11 ppm/°F  2 ppm/°F
 Compressive Strength  > 500 psi  > 500 psi
 Tolerance (As-Printed)  +/- 0.015”  +/- 0.015”
 Coating Options  Teflon tape or spray on soluble coating
 Washout Method  Room temperature tap water



Washout Process

 3D Printing Process
 3D Printed Mandrel
 Coated Mandrel
 Filament Winding
 Mandrel is Cured
 Final Part with Sand “Washed Out”

Benefits of Printed Washout Tooling

    • 350oF Use Temperature

      • Washes out with water

        • Low or High CTE print media

          • Low cost

            • Fast manufacturing time

              • Design complexity

                • Reusable media

                  • Autoclave processing compatibility



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