Reference free part encapsulation: Materials, machines and methods

Reference Free Part Encapsulation (RFPE) is an automatic, universal workholding process developed by researchers at the Massachusetts Institute of Technology and the University of California-Berkeley. The process encapsulates the stock by freezing it in a low melting point material during machining and transfers datums from one setup to another by refilling and restoring the encapsulation to a known shape after each setup. This paper describes the encapsulator materials and machines developed to test and demonstrate RFPE. The encapsulation material must satisfy stringent thermal properties, and a process is described that concludes that the tin–bismuth eutectic is ideal. The similarities of the encapsulation process to manufacturing processes such as die casting and injection molding are considered; however, it is shown that many intrinsic differences exist between the encapsulation process and injection molding or die casting. Two encapsulation machines are presented. The first is a larger encapsulation machine capable of forming encapsulations with a 6 in. by 6 in. footprint. The second, a much smaller portable machine capable of forming encapsulations with a 2 in. by 2 in. footprint, is also presented. Special features of each encapsulation machine are highlighted and various design decisions are discussed.