The Leader In 3D Printed Tooling Innovation

Tools In Half the Time & Half the Cost

Catalysis Is A Complete Solution Tool Maker That Uses 3D Printed Tooling

We are the leader in thermoforming tooling innovation. We are leading the charge of bringing additive manufacturing to the thermoforming industry. Our 3D printed tooling is manufactured for a fraction of the time and cost of traditional tooling, with much more durability and quality when compared to traditional tooling.

Vacuum Forming Tooling

The vacuum forming process involves heating a plastic sheet until it is soft and stretched onto a single surface mold. Where vacuum is applied to form the plastic over the mold surface to create the desired part.

Characteristics of a Catalysis 3D printed vacuum forming tool:

100% porous structure pulls a better quality part faster
Made from a non-conductive material so no cooling is required
Fully isotropic build avoids any delamination
Light sand blast finish (100RA) eliminates A-side witness marks
Highest production project ran 4,500 parts (.187″ ABS)

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Foam Part Manufacturing Tooling

When it comes to foam part manufacturing tooling, we can either provide one tool for one part, or all tools needed for the entire vehicle in a manufacturing time of 3 weeks for prototype/low volume parts. Our 3D printed tooling technology enables tool designs that are not possible with traditional CNC manufacturing and has consistent thermal profiles by using integral copper water lines so each tool has the same thermal mass (similar shell thickness). Our 3D printed foam part manufacturing has a glossy tool surface finish, 85D scale hardness, strength required for 10-15 psi of foaming process, has a fully isotropic print structure and there is no delamination of the tool, meaning the tool will not separate (plastic tools will eventually separate).

Foam Part Manufacturing Tooling Applications include:

Automotive Seating
Airplane Seating
Motorcycle Seating

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NVH (Noise, Vibration, Harshness) Part Manufacturing With Compression Forming Tooling

Compression molds for NVH (noise, vibration, harshness) barrier materials are used to reduce noise & vibration. The compression forming process is high force with a press, using 2 tools + heated material. Catalysis 3D printed NVH part manufacturing compression tooling has 85D scale hardness and the strength required for 20-40 tons of force in the manufacturing process. NVH barrier parts are typically made with steel tooling with a tool lead time of 8-12 weeks. Catalysis 3D binder jet compression tooling has a lead time of 3-4 weeks.

NVH Part Manufacturing Tooling Applications Include:

Automotive Sound Deadening Parts
Airplane Sound Deadening Parts
Appliance Insulation

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Bladder Hydroforming Tooling & Parts

The bladder hydroforming process is used for forming metal parts with a single sided tool. The bladder forms the metal over the tool, inflating to 11,000+ PSI to accurately form the metal part over the tool. Bladder hydroforming is a slower cycle time (1-2 minutes) commonly used for aerospace but is a good application for automotive, agricultural, and other industries for part development and low production.

Characteristics of a Hydroforming tool:

Fully isotropic in strength to withstand high forming pressures of 11,000+ PSI
Secondary coating on tool which eliminates defects on finished part
Tool is capable of running prototype/low volume parts
Tool cost & time is less than 50% of existing conventional prototype tooling
Catalysis can offer tooling and parts

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Twin Sheet Tooling

Twin sheet thermoforming is the process of vacuum forming 2 sheets of plastic together simultaneously. The process involves the use of two molds. Once formed, the top and bottom molds are brought together quickly, so as not to lose surface temperature.

Characteristics of a Catalysis 3D printed twin sheet tool:

100% porous structure pulls a better quality part faster
Made from a non-conductive material so no cooling is required
Fully isotropic build avoids any delamination
Light sand blast finish (100RA) eliminates A-side witness marks

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Drape Forming Tooling

Drape forming is a process where a plastic sheet is heated then formed over a tool to make a part without the use of a vacuum. Our process allows us to get the tools printed, processed and to our customers as quickly as possible.

Characteristics of a Catalysis 3D printed drape forming tool:

Fully isotropic build avoids any delamination
Light sand blast finish (100RA) eliminates A-side witness marks
Capable of high volume production
Extremely fast print time allows us to get the tools printed, processed & to our customers as quickly as possible

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Fixturing

A variety of fixtures can be made for CNC trimming, assembly, and part check purposes. The fixtures can accept and have rubber gaskets installed. In addition, the fixtures can be mounted to a box or mounting plate based on the customers needs. All fixtures use the same 3D printing technology, have the same design in order to save cost & time and are delivered together. Since all of the tools are made at the same time, this allows for an easier, more efficient time saving streamline process.

Fixtures Include:

CNC Trim Fixtures
QC Check Fixtures
Assembly Fixtures
Draw Boxes

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Composite Part Manufacturing Tooling

Composite fabrication process involves a tool to shape the resin and reinforcement. A tool is required to give the resin/fiber combination its shape prior to enduring the curing process.

Characteristics of a Catalysis 3D printed composite part manufacturing tool:

Fully isotropic build avoids any delamination
Secondary coating gives a class A tool finish
Capable of high volume production
Extremely fast print time allows us to get the tools printed, processed & to our customers as quickly as possible

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Vacuum Check

We always talk about how our tools are 100% porous and a part of our QC process is confirming vacuum function. Here’s a part of our test procedure testing the vacuum function of a 3D printed tool with no vacuum holes.

Our technology has allowed us to truly be a One-Stop-Shop for all of your tooling needs

Catalysis Additive Tooling was founded by utilizing a collective 60+ years of automotive engineering, tooling, and new model development experience. That experience combined with 10+ years of Additive Manufacturing/3D Printing research has allows us to develop the foundation of Catalysis and being able to offer our customers a complete solution to support their Development and Production needs.

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