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Our Process

 

Ready to challenge the status quo and design new processes? Rapid Discharge Forming (RDF) is a revolutionary processing platform for manufacturing of metallic components that disrupts conventional metal manufacturing techniques.

 
 
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A New Alternative To Old

die casting
metal injection molding
Forging
Machining

 
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Claim To Fame: Speed

RDF produces net-shaped parts in less than 1 second by leveraging the unique properties of metallic glasses

 
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Favorite Bragging Rights

Speed per part less than 1 sec
air processing
electronic cleantech
high precision
high performance
high throughput
low cycle time

 

 
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Two Easy Steps

1. a fast discharge of electrical current rapidly heats the metallic glass feedstock. processing takes place at viscosities of 100 to 10,000 Pa.s.

2. a deformational force or pressure is applied to shape and form the metal into a net shape component. 

 
 
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Brought To You By

 

RDF 30kJ BETA

State of the art custom built MACHINE for mid-size human operator

  

 

Maximum
Processable Weight

  • 55g Nickel

  • 90g Zirconium

  • 225g Platinum

  • 375g Gold

Running
Specs

  • 30kJ energy capacity

  • 20tn clamping force

  • 8000lbf injection force

  • 23in/sec injection speed

  • all processable alloy range

 
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Production Cycle Breakdown

 

Follow along

 

Loading

An amorphous metal feedstock is loaded into a barrel connected to the mold cavity. The mold is closed and a clamping force (Fm) is applied. The feedstock makes electrical contact with two electrodes that approach it axially on either end. This contact is maintained by application of contact force (Fc).

Heating

The electrodes are connected to a capacitor bank storing sufficient energy to bring the feedstock to its processing temperature. A high current, with a peak between 10 to 20 kA, is discharged through the feedstock heating the material to its processing temperature in 20-30 ms. 

Injection

One electrode - also serving as a plunger - drives the softened metal through a gate and into the mold cavity. The entire injection process takes place in 50-100 ms. 

Cooling

Once the injection stroke is complete, a packing force (Fp) is maintained by the plunger as the material cools in the mold. The time required for cooling depends on part geometry but varies between 500 ms to 5 s. 

Ejection

Once the parts have cooled, the mold is opened and the parts are ejected. 

 

Setup

Subsequently, the electrodes are repositioned to accept a new feedstock. The capacitor bank is recharged for the next molding cycle.