re: Pulley prototypes? Stamping Q's

From: Jürgen Bauer (
Date: Fri Feb 13 1998 - 12:17:58 EET

 Dear Dan,

LOM can make it for hydroforming, but only for simple geometry (bending rather than drawing) and limited pressure, i.e. 150 bar.
With your 3mm steel drawn 50mm, you easily top 100 bar on a hydroforming press.
In short: Forget LOM for this case.

Your quickcast idea could work.

But why cast metal ?
Build you pulley with SLA, then use a special drawing die resin from Ciba, a low-temperature alloy by MCP or even a Concrete from Densit AS, Denmark.
But, to be honest, I am not sure about tool wear in YOUR 3 mm steel - case.

So, I feel that you could end up high speed milling a tool. This could be done from hard wood (i.e. from OBO), which has excellent friction properties.

A job-shop in Germany that is qute "high-tech" in this business would be HAGO, tel. +49 7741 6003 - 0, fax +49 7741 6003 - 33
You could contact the founder, Mr. Haberstock, directly at

To find a fluid cell press nearby your place, ask Mr. Johannisson from ABB pressure systems AB, Sweden, tel. +46 21 327252, fax +46 21 141817

To read more about the subject, have a look at

With kind regards
Juergen Bauer

Siemens EC CS Automotive, Siemensstr. 13, 67346 Speyer, Germany
Tel. +49 6232 30 2501, Fax +49 6232 30 2110

-----Ursprüngliche Nachricht-----
Gesendet am: Freitag, 13. Februar 1998 09:59
An: 'RP Mailing List'
Cc: 'Steve Sadler'; ''
Betreff: Pulley prototypes? Stamping Q's

Hello all,

I need to make about 30 pulleys for functional tests. These have to be production intent, so machining is out. The mass prodution method is stamping then rolling. One piece of 3mm steel drawn about 50mm -- no joints. I'm not a stamping guy, so I'm not especially familiar with this process and I don't visit the production facility until late next week. I'm trying to get a head start here.

Has anyone out there used a LOM pattern as a tool for hydroforming? Any hydroform companies you can recommend (as close to SE Asia as possible!!!)?

Could one use SLA QuickCast to make a near-net-shape tool insert, finish it then use the normal press? Would the investment cast tool be strong enough? I'm interested in speed rather than cost, even though I suspect that this will be cheaper, too.

Any thoughts?

Dan Davis
Division Head, RP&M
Perusahaan Otomobil Nasional Berhad (PROTON)
Hicom Industrial Estate
Batu 3 PO Box 7100
Shah Alam, Selangor D. E.
+60 3 515-3906 direct line
+60 3 515-2380 direct fax
+60 12 277-5770 hand phone

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