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ContentsMTT Company Profile 4MTT Selective Laser Melting 6MTT Vacuum Casting PU Nylon & Wax 8MTT Semi Automatic Moulding Machines 10MTT Metal Part Casting 12MTT Small Injection Moulding Machines 14MTT Sheet Metal Tooling Systems 1503

Company ProfileMTT Technologies Group was formed following the sale of the MCP minor metalsand chemicals business in 2008, with the MCP name being retained by the newowners. MTT Technologies Group was created to maintain and build on the legacycreated by MCP HEK and MCP Tooling Technologies in the rapid prototyping andrapid manufacturing sectors, where the Vacuum Casting, Selective Laser Melting,Rapid Tooling and Injection Moulding products are sold.The separation has allowed MTT to focus effort and investment on developingand manufacturing products and services that are sold through an establishednetwork of subsidiary offices, agents and distributors.A key part of our strategy is to maintain and further develop our relationshipswith key development partners in both universities and institutes, to ensurethat MTT is well placed to bring technologies and processes to market.Our philosophy is to provide turn-key packages that meet and exceedour customers’ needs and expectations.04

At MTT our most important asset is our people and our biggest challenge is tocommunicate the benefits of our technologies and services to our market place.This brochure is designed to give an overview of all the products and technologiesavailable from the MTT Technologies Group. Product specific brochures aredetailed throughout this document.Our history as MCP is something we are very proud of and has been created as aresult of the combined efforts of many people over several decades. The task forMTT is to continue these efforts and grow a strong and vibrant business with thecustomer at the heart of everything that we do.Can we help you?For more information about the history of our company and new productdevelopments, please visit our website at: www.mtt-group.com05

CAD driven direct manufacturingin a wide range of metalsMTT Selective Laser MeltingMTT’s Selective Laser Melting (SLM) is a pioneering additive manufacturingprocess capable of producing fully dense metal parts direct from 3D CADusing a high-powered fiber laser. Parts are built from a range of fine metalpowders that are fully melted in a tightly controlled atmosphere layer bylayer in thicknesses ranging from 20 to 100 microns. The current rangeof machines are the third generation designs and, following several yearsof detailed market feedback from key development partners and clients,now represent state of the art manufacturing systems. Key featuresproviding significant enhancements over previous models include variablepowder delivery, ultra low Oxygen content in the build atmosphere and anunparalleled safe change filter system to minimise user materials contact.The range comprises the SLM 250 and the SLM 125, both of which featurevacuum technology and low gas consumption. The machine has beendesigned for ease of use within a manufacturing environment and featuresa touch screen interface and various menu options for machine preparationand clean down. Machine robustness has been given a high priority adoptinga ‘machine tool’ approach to use and serviceability. Consumables costs areminimised through careful design and features such as the soft re-coaterblade, that can be rotated several times before replacement, and the use oflow cost filter elements right through to low gas consumption, all contributeto system reliability and low cost of ownership.MTT’s SLM systems have always processed a wide selection of materialsand the new range is no exception, but with the additional benefits of rapidmaterials change over via a cassette type materials delivery system;particularly useful where materials development or product variety areneeded. The capability to safely process reactive materials such as Titaniumand Aluminium is a standard feature on MTT SLM machines. In particularthe gas knife that clears away reactive sooty emissions and the heatedbuild plate are both pre-requisites for the successful processing ofboth materials.Both the new machines feature a fully welded vacuum chamber, enablinglow-pressure evacuation followed by a recharge with high purity Argon gas.The gas consumption rate, after the initial chamber flood, is extremely low,and allows operation at Oxygen concentrations below 50 parts per million– a crucial factor when processing reactive materials such as Titaniumand Aluminium; and contributing significantly to material integrity andmechanical performance.06

All file preparation is completed off-line through a choice of interface,either Marcam Autofab software or via Materialise Magics. Once completethe build file is uploaded to the machine via a secure network or directconnection. Product traceability has been improved by the addition ofprocess data and event logging as standard with various additional processcontrol options on request.Further information on this technology can be found in our productspecific brochure.Removeable Powder Cassette – SLM 125English 2531/3enGerman 2531/3deSLM TECHNICAL DATASLM 250 SLM 125Build volume250mm x 250mm x 300mm(x,y,z) z extendable to 400mm125mm x 125mm x 125mm(x,y,z)Fiber laser power 200 – 400 W 100 – 200 WLayer thickness 20 to 100µm 20 to 100µmStandard laser spot size50 microns diameterat powder surface30 microns diameterat powder surfaceAvailable materialsMaterials in developmentStainless Steel 316L and 17-4PH, H13 Tool Steel, AluminiumAl-Si-12Mg and Al-Si-10Mg, Titanium CP, Ti-6Al-4V and Ti-6Al-7Nb,Cobalt-Chrome (ASTM75), Inconell 718 and 625We have a range of materials in development, please contactMTT for an up to date list.07

High quality parts in a range of replicamaterials, glass filled Nylon and wax mastersfor investment castingMTT Vacuum CastingWhen MTT introduced its range of Vacuum Casting machines to the market in1987, ‘24 hours from pattern to part’ was nothing short of a revolution.Since that time, a programme of continuous product development andinnovation over the last 20 years, coupled with applications training andmaterials supply, has secured MTT’s position as undisputed market leader.Most recent developments include Vacuum Cast glass filled Nylon, producingcomponents that exhibit properties far in excess of other rapid prototypingtechnologies. All of this is possible without hard steel tooling and theassociated lead times and costs.The process involves encasing a master model in Silicone rubber, a vacuumis then applied to the mould, following this the mould is cured in a oven. Oncecured the mould can be cut open, at which point the master model is removedleaving a mould cavity perfectly replicating the master model.Master models can come from a range of sources, the most common beingStereolithography models, but the increasing range of CAD driven 3D printersare also a useful source. The quality of the master model dictates part qualityand complexity can be accommodated through multi segment moulds.Everything from industrial components, consumer products, lenses and smallbatch production can be achieved using the Vacuum Casting process. Typicallybetween 30 and 50 colour matched parts can be produced from a singlemould with first off parts available within two to three days.Further information on this technology can be found in our productspecific brochure:English: 2531/3 en.German 2531/3 de.08

Wide range of machinesand applications5/01, 5/04 and 5/05The range of MTT Vacuum Casting machines includeschamber capacities from ~500mm³ up to severalcubic meters.All feature PLC control and options include:• Nylon casting module• Heated Cup for wax masters• Vario Vac technology to aid moulding of viscous materialsTypical applications include:• High quality prototypes for product design verification• Small batch production for bespoke products• Functional Nylon components in a range of grades –particularly good for living hinges and high strength• Automotive ‘hot test’ and specialist manufacture• High quality wax masters for investment casting• Soft feel components using Vario Vac technology• Production of EP tooling resin mouldsPlease see product specific brochure for full rangeof machine sizes.09

Prototype and batch production thermoplasticinjection mouldings from low cost mouldsMTT 100 KSA Semi AutomaticInjection Moulding MachineDesigned for low cost tooling in either Aluminium or epoxy resin the 100KSAoffers a versatile platform for components from 0.5 grams up to a maximumof 180 grams depending on configuration.Capable of providing 20 Tonnes of clamp force the 100 KSA relies uponmanual mould insertion followed by an automatic moulding cycle, providinggood process stability. Alternatively the moulding cycle can be run manually,particularly useful when setting up moulding parameters. A range of plungersizes is available for different shot volumes and injection pressures.It is ideally suited to batches of 50 to 1000 and can also be used forover-moulding inserts.MTT EP Tooling Resinfor rapid toolingA low cost alternative to hard steel tooling. EP tools are produced by ‘casting’two halves of a mould against a master model in a similar way to the siliconetools used in Vacuum Casting.The major difference is that the first half of the mould is cast against a mastermodel set in a split line face. The second half is then cast against the first halfwith the master model positioned in the cavity.Major advantages include significantly reduced lead times and the abilityto replicate complex geometries and surface features. It is also possible tocreate side actions for hidden features. A common practice is to create hybridtools that include metallic components that are cast in when the mould isproduced. EP resin can also be used on conventional moulding machines.10

Prototype and batch production blowmouldings from low cost mouldsMTT 50/E Semi AutomaticBlow Moulding MachineThe MTT 50/E Blow Moulding machine is specifically designed to fill a nichefor production of short series hollow forms, where the set up time and toolingcosts of a conventional blow moulding machine are prohibitive.The machine is semi automatic with operators unloading parts and initiatingan automatic moulding cycle, ensuring product consistency. It is ideally suitedto batches of up to 1000 and does not require preforms. Materials are fed by ascrew plasticiser and include PE, PP and HDPE.Further information on all of these technologies can be found in our productspecific brochure:English: 2531/2 en.German 2531/2 de.EP Tooling Resin – the process1. Use any type of rapid prototypingmodel including wood, plaster,leather, silicone or resin.Fit metal inserts if required.2. Mix EP Tooling Resin with Hardenerand degas. Fix casting frame andcooling pipes. Cast the EP ToolingResin. Degas again.3. Fix upper casting frame. Cast EPTooling Resin. Degas again.4. Remove the casting frame.5. Heat cure the mould in the oven.6. Completed injection tool.11

High quality parts in non-ferrous metalsin 3 to 5 days using wax masters from theMTT Vacuum Casting processMTT MPC Metal PartCasting SystemFrom master models to investment cast metal parts in 5 days using waxesfrom the MTT Vacuum Casting Process and the MTT Metal Part CastingSystem. It is also possible to go direct to part using master models from manyof the commercially available model making systems.The system is particularly well suited for thin wall, complex geometries anddelivers a high quality surface finish similar to a pressure die casting, fromhigh quality master models.There are several machines in the range with casting capacities from 3 to 15litres. A system includes the casting unit, embedding unit, kilns for theburn-out process and all the necessary finishing and cleaning equipment.Further information on this technology can be found in our productspecific brochure:English: 2531/5 en.German 2531/5 de.12

Case Study: Three versions of a “handlebar jig” used to assist athletes inoptimising their own riding positions, were produced in record time for theBritish Cycling Team using a combination of MTT’s vacuum casting andmetal part casting technologies. The first PU resin version was produced injust five days after receiving the CAD files. The 8-component system was sosuccessful in early tests that it was decided to build two further versions, onewith an aluminium stem holder and one entirely from aluminium to increasethe overall strength of the jig. To achieve another high speed turnaround,MTT’s Metal Part Casting process was used, which involves casting waxes inthe silicon tools and then setting up the wax parts on an investment castingtree. The wax tree is then encapsulated under vacuum in ceramic slurry,which then goes through a firing process. The ceramic flask was then castin A357.1 Aluminium, again under vacuum, and the finished parts water beadblasted to give them a polished sheen finish. The revised versions of the jigwere presented just seven days after receipt of the new drawings.13

A range of small footprint injection mouldingmachines for full-scale production of smalland micro parts.MTT 12/90 range of InjectionMoulding MachinesThe 12/90 range of injection moulding machines are ideally suited for theproduction of small and micro components. The machines are easy to operatethrough the PLC driven touch screen interface, with various levels of userprivilege available via password protection.All machines feature a screw and plunger arrangement contributing toefficient colour mixing and plasticisation and high accuracy dosing. All benefitfrom 4 zone closed loop PID temperature control with capacity for furtherzones for tool heating and hot runner systems.Mould safety is standard on all machines and the option to extract SPC datacan be configured on the 12/90 HSE all electric machine.The range includes 12/90 HSE and 12/90 Micro all -electric machines and the12/90 HSP pneumatically powered bench top machine. The VSP over mouldingmachine completes the range.Further information on MTT Injection Moulding Machines can be found in ourproduct specific brochure:English: 2531/1 en.German 2531/ de.14

Prototype sheet metal forming toolsin as little as 3 to 5 days using a rangeof low melting point alloys.MTT Sheet Metal Tooling SystemSheet metal form tooling produced using MTT137 low melting point alloy isused by many automotive manufacturers including BMW and Chrysler forapplications where between 20 and 200 short series or prototype pressingsare produced when developing new models.Sheet metal forming tools are produced using low melting point alloys castagainst a master model or part. The process is similar in principle to the EPtooling process where the two halves of a tool are created using a sequentialprocess. The punch and die are created by suspending the model in a castingframe; the low melt alloy is then cast against this model to produce the firsthalf of the tool. Once cool the model can be removed and the first half is thenlaid up with pattern makers sheet wax to the desired thickness, the secondhalf of the tool is then cast by pouring low melt alloy against the wax.Once the process is complete the tool can be on the press in a matter of hoursand like EP, tool life can be extended by incorporating steel inserts for morecomplex and detailed features.MTT can supply a range of melting tanks from 100kg up to 60 tonnes to suitapplications from simple brackets to complete automotive floorpans.• Large automotive press tools in days• Dimensionally extremely accurate• No distortion• No finishing required• Low processing temperature• Non toxic• Completely re-usabale15