Rapid prototype firm CRDM finds new application for additive layer manufacturing

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CRDM, which claims to be the UK's longest standing provider of rapid prototyping and manufacturing, has initiated a project to introduce a new manufacturing method for electronic packages that will eventually enable the production of high performance electronics packages in 50% silicon aluminium alloy – something that could offer exceptional benefits to the high power switching/microwave electronics industries.

CRDM has been closely associated with the 'traditional' mechanical engineering market, using rapid manufacturing to produce mould tool dies, as well as metal products, while also offering a rapid moulding service. It also provides rapid prototyping services for physical products. The organisation instigated this latest project to investigate how to remove heat from electronic devices, in order to avoid drops in efficiency. The global market for thermal management currently stands at a staggering £1 billion, so the improvement of cooling high power switching devices has the potential to lead to major energy savings. CRDM collaborated with several leading organisations from the electronics industry to work on individual elements of the Additive Layer Manufacturing (ALM) technique. The project, which was funded by the Technology Strategy Board (TSB), demonstrated that it is possible to selectively laser melt high silicon aluminium powders to produce artefacts. Specific benefits have already been established for a number of individual markets ranging from aerospace through to avionics.