WO2015108959A1

WO2015108959A1 - Internal inductive heating of additive manufactured parts and tools

Info

Publication number: WO2015108959A1
Application number: PCT/US2015/011381
Authority: WO
Inventors: Brennon White; Eric Michalak; Lu Feng; Mason PIKE; Eve Fabrizio
Original assignee: Johnson Controls Technology Company
Priority date: 2014-01-14
Filing date: 2015-01-14
Publication date: 2015-07-23

Abstract

A part or tool (1, 12, 14) and a method of forming a part or tool and a part or tool system (100) are provided. The part or tool is formed of a tool material (4, 40, 42, 45, 46) including a tool surface material defining a tool surface (16) to be heated. Internal ferretic or magnetic material (2) is embedded in the tool material or held in position relative to the tool material at a location adjacent to the tool material and spaced away from the tool surface. The internal ferretic or magnetic material has a shape relative to the tool surface to optimize heat transfer in a direction of the tool surface. The internal ferretic or magnetic material has particles of a specific frequency to give off heat upon being subjected to the alternating magnetic field with a same resonant frequency.

Description

INTERNAL INDUCTIVE HEATING OF ADDITIVE

MANUFACTURED PARTS AND TOOLS

FIELD OF THE INVENTION

[0001] The present invention relates to parts or tools that must be heated by a heating device or must include a heating device.

BACKGROUND OF THE INVENTION

[0002] Heating of parts or tools can be inefficient. Often the heat will need to be transferred through a large thicknesses of material due to robustness requirements related to the heater or the tool that is being heated. This results in heat losses and bulky and sometimes heavy tools and heating arrangements.

[0003] Heating of parts or tools is often done using a separate heating system. This increases labor and material costs to manufacture the parts of the system or the tools. The heat may not be easily controlled inside of the parts or inside of the tools, using such seperate heating systems. This can be due to packaging, manufacturing, and material constraints.

[0004] Water jackets, for heating tools, add weight to the heating system. Such water jackets hinder tool design by restricting vent port locations. The ideal object shapes may also not be achievable due to the need to position water jackets in given locations. For instance, a molded material may not fill out a small pocket in a mold tool as it may shrink away from that area due to rapid cooling. [0005] Additive Manufacturing (AM) is an appropriate name to describe the technologies that build 3D objects by adding layer-upon-layer of material, whether the material is plastic, metal, concrete or even biological material (human tissue).

[0006] In common to AM technologies is the use of a computer, 3D modeling software (Computer Aided Design or CAD), machine equipment and layering material. Once a CAD sketch is produced, the AM equipment reads in data from the CAD file and lays downs or adds successive layers of liquid, powder, sheet material or other, in a layer-upon-layer fashion to fabricate a 3D object.

[0007] The term AM encompasses many technologies including subsets like 3D Printing, Rapid Prototyping (RP), Direct Digital Manufacturing (DDM), layered

manufacturing and additive fabrication.

[0008] AM applications are limitless. Early use of AM in the form of Rapid

Prototyping focused on preproduction visualization models. More recently, AM is being used to fabricate end-use products in aircraft, dental restorations, medical implants, automobiles, and even fashion products. The 3D printing industry has been working on printing multiple materials in one process for years. A recent development is the use of conductive polymers and ultraviolet cured metallic inks to create circuits.

[0009] US 3,391,846 discloses a method of heating a material comprising associating the material with finely divided, multidomain, non-conductive antiferromagnetic particles so that heat generated in the particles is transferred to the material. The particles are subjected to an alternating magnetic field having a frequency of at least 10 megacycles per second. The temperature of the particles increases towards a maximum temperature and the material is heated thereby.

[0010] DE 33 14 824 (Al) discloses an apparatus for heating the interior of containers. A conveyor, mixing tool or stirring mechanism is heated with the aid of an electromagnetic field which generates eddy currents. The container is surrounded by induction coils and the walls of the container may be composed of a thin-walled standard steel and the conveyor, the mixing tool or the stirring mechanism of a magnetic material. The walls of the container may also be composed of a non-magnetic material, for example ceramic material, refractory material, a non-magnetic steel alloy or a non-ferrous metal, and the conveyor, the mixing tools or the stirring mechanism of a magnetic material.

[0011] DE 10 2006 023 383 (Al) discloses a method for the production of plastic parts by injecting a molten thermoplastic molding material into a mold cavity, in which the material contains particles which are heated up directly by the action of alternating electrical and/or magnetic fields in parts of the mold cavity. A device for generating an alternating E/M field acts at least partly in the cavity, in which at least those parts of the mold which are exposed to the field and in direct thermal contact with the cavity are designed so that they are not substantially heated by the action of the field thermoplastic molding materials containing particles.

[0012] US 7,651,580 discloses nanoparticulate preparations containing at least one mixed metal oxide in the form of supramagnetic, nanoscale particles. Methods are disclosed for heating such a preparation, and methods are disclosed for producing and dissolving adhesive compounds on the basis of the preparations.

[0013] US 8,524,342 discloses plastic composite moldings obtainable via welding in an alternating electromagnetic field. The weld is obtained with the aid of a plastic material which comprises nano-scale, magnetic oxidic particles, which are composed of aggregated primary particles. The primary particles are composed of magnetic metal oxide domains whose diameter is from 2 to 100 nm in a non-magnetic metal oxide matrix or non-magnetic metalloid oxide matrix.

SUMMARY OF THE INVENTION

[0014] The invention provides a method using Additive Manufacturing (AM) (also known as 3D printing) to produce a component or tool that includes ferretic or magnetic materials and then provides inductive heating to provide heat (for heat transfer) in an efficient and effective way. The method allows for the quick production of complex tools including tools that require a low temperature (to keep polymers from melting). The method also allows for the quick production of complex metal or composite tools, including tools partially made of aluminum or an aluminum alloy (used for high temperature execution).

[0015] Inductive heating only requires that power be used when heat is needed. This differs from past arrangements in which heat is generated during non heat load times. As induction requires ferretic or magnetic compounds this type of material is different from existing metallic inks as the primary focus is on the magnetic signature and not the conductivity of the ink.

[0016] According to another aspect of the invention, ferromagnetic particles are provided in a plastic materials tool, particularly within a cavity formed within the plastic materials tool. The tool is especially a foam mold tool. The tool is at least partially made of non-magnetic (plastic) material with embedded (ferro) magnetic particles. The tool is part of a system or device that also comprises an inductive heating means, such as one or more coils for generating a magnetic field.

[0017] A preferred embodiment may comprise different particle content, such as a variation of the mass/volume of the embedded (ferro) magnetic particles, and/or different inductive forces at different locations of the tool, depending on the local heat requirements at the different surface areas of the cavity. The power, location and shape of the induced magnetic field may be changed and controlled to change the heat at the embedded (ferro) magnetic particles. [0018] The induction heating device uses alternating magnetic resonance coils to create a time varying magnetic field. When the magnetic particles of a certain alternating resonant frequency are subjected to the alternating magnetic field with the same resonant frequency the particles vibrate and give off heat. This allows particles to be placed within a part or tool at a specific location where the heat is desired. It is also possible to vary an amount of heat in a specific proximity by changing or varying an amount of particles near to that proximity. Higher concentrations of particles create more heat, while lower

concentrations create less heat.

[0019] The invention forms the tool with the ferretic or magnetic material inside of a part of the tool or within the tool utilizing Additive Manufacturing. While coating the surface of the tool with a magnetic material can be done, Additive Manufacturing allows for a deposition of materials underneath the surface. This gives the magnetic particles protection against wear and increases durability. [0020] An added benefit is related to there being no physical connection to the tool for the generation of the heat at the tool. The invention eliminates the typical water jackets and also reduces weight while improving the ability to locate features like venting ports in locations that could not have been vented before.

[0021] The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 is a schematic sectional view of a tool system, including a tool with a tool surface and ferretic or magnetic material embedded below the surface and with an inductive heating means, such as one or more coils, according to the invention;

[0023] Figure 2 is a sectional view, taken along line II-II of Figure 1, showing the tool with ferretic or magnetic material embedded below the surface of the tool and in or adjacent to chambers that provide a free space or cavity allowing for thermal expansion differentials of materials;

[0024] Figure 3 is a schematic sectional view of a tool system with mold tools and with a heating means with plural coil arrangements;

[0025] Figure 4 is a schematic sectional cut away view of a tool showing embedded ferretic or magnetic material relative to a tool surface;

[0026] Figure 5 is a schematic sectional cut away view of a tool showing embedded ferretic or magnetic material relative to a tool surface;

[0027] Figure 6 is a schematic sectional cut away view of a tool showing embedded ferretic or magnetic material relative to a tool surface;

[0028] Figure 7 is a schematic sectional cut away view of a tool showing embedded ferretic or magnetic material relative to a tool surface;

[0029] Figure 8 is a schematic sectional cut away view of a tool showing embedded ferretic or magnetic material relative to a tool surface;

[0030] Figure 9 is a schematic sectional cut away view of a tool showing embedded ferretic or magnetic material relative to a tool surface; [0031] Figure 10 is a schematic sectional cut away view of a tool showing embedded ferretic or magnetic material relative to a tool surface;

[0032] Figure 11 is a schematic sectional cut away view of a tool showing embedded ferretic or magnetic material relative to a tool surface;

[0033] Figure 12 is a schematic sectional cut away view of a tool showing embedded ferretic or magnetic material relative to a tool surface; and

[0034] Figure 13 is a schematic sectional cut away view of a tool showing embedded ferretic or magnetic material relative to a tool surface.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0035] Referring to the drawings, Figure 1 shows a part or tool 1 with internal magnetic material 2. The magnetic material 2 has a shape 3 designed to optimize heat transfer in a desired direction. An example would be having the material close to, but not on, the inner surface of a tool. This allows even heat transfer in the tool with less heat lost to the outside of the tool. As the material 2 is embedded and spaced inwardly from the surface, there will be less wear on the magnetic material. [0036] The part or the tool 1 is constructed with multiple material types that perform different functions. The material 2 is provided embedded as channels or regions of magnetic material 2 within an insulative material, particularly a polymer 4. The material 4 may also be heated. However, the material 4 may be insulative material with heat being provided without contacting the tool by sending the tool past, or subjecting the tool to, a heating means such as an antenna array of inductive coils 5.

[0037] The part or tool 1 is constructed with internal chambers (cavities) 6 allowing for thermal expansion differentials of materials. The magnetic material 2 is shown with the shape 3 in a region near the inside 10 of the tool 1. Particularly, the magnetic material 2 is in a space (hollow channels 6) with a cavity7 of any suitable shape behind the magnetic material 2. This provides an area to allow for thermal expansion of the material 2 relative to the material 4. Other arrangements may be provided such as each embedded body of material 2 being in a cavity 7 that is at least slightly larger than the volume of the embedded body of material 2. The empty space of the cavity 7 insulates the heat from conductive heat transfer to the outside 9 of the tool. This directs thermal heat transfer as shown by heat pattern 8 by conductivity and further optimizes heat transfer efficiency.

[0038] The part or the tool 1 is advantageously additive manufactured (3D printed) allowing high resolution as to placement of materials. This allows the material 2 to be completely contained within the tool 1. The amount of material, the shape, the size of the cavities (relative to the material 2), and locations of the material can be accurately controlled during the additive manufacturing process. This allows material placement in locations and shapes that are not possible with conventional manufacturing processes.

[0039] The part or tool may also be manufactured by installing the magnetic material by creating a part or tool with hollow channels 6 that would be open to allow the drawing (as with a vacuum) or pushing of magnetic material through the channels 6. This procedure may be used in combination with the additive manufacturing process. Further, some parts may be formed in advance as a substrate of a partial tool portion with the additive manufacturing process adding additional material to form the final tool or product. [0040] A receiver coil 90, of conductive material, may also be incorporated inside of the tool to inductively transfer power from a source coil 5 or transmitter to the receiver coil 90.

[0041] Figure 3 schematically shows a mold tool system 100 that includes at least one tool, such as an upper mold tool 12 and a lower mold tool 14. The mold tools 12 and 14 comprise a mold tool material including a mold tool surface (and/or surrounding) material 11 defining an inner surface 16. The inner surface 16 of mold tool 12 and mold tool 14 cooperate to define a mold cavity 18. The mold tool 12 further comprises internal ferretic or magnetic material 21. This material 21 is advantageously 3-D printed along with mold surface material 11 such that the magnetic material 21 is completely embedded within the surface material 11.

As mentioned above, and as discussed further below, the upper mold tool 12 may include other features such as one or more cavity to allow for relative thermal expansion of magnetic material 21 and mold surface material 11. Further, a heat directing element may be positioned relative to the tool material 11 and relative to the internal ferretic or magnetic material 21 to at least one of inhibit conductive heat transfer in a direction toward the outside of the tool or direct conductive heat transfer in a direction toward the inside of the tool to optimize a direction of heat transfer. The heat directing element may be material to reflect heat, which material may also be 3-D printed to position the heat directing element relative to the surface and/or surrounding material 11 and the magnetic material 21. Further, the heat directing element may also be a cavity 7, which will restrict heat transfer in a direction away from the cavity 18.

[0042] The mold tool system 100 also includes a plurality of inductive coils 52, 54, 56 and 58. The inductive coils are arranged or distributed so as to optimize the formation of one or more magnetic fields, such that the particles of the magnetic material 21 resonate in an optimal way, at the natural frequency of the of magnetic material 21. These inductive coils

52, 54, 56 and 58 may be controlled by a control device 110. The particles of the magnetic material 21 have a specific resonant natural frequency at which they vibrate and heat up. The one or more inductive coils 52, 54, 56 and 58 each produce a magnetic field that alternates - changes polarity - at the same frequency as the natural frequency of the particles. This essentially shakes the particles, which are confined in position (so they cannot move much), so energy is dissipated in the form of heat. The mold tool 12 is shown with a receiver coil 90, that can be inductively coupled with one or more of the inductive coils 52, 54, 56 and 58. The receiver coil 90 may then provide electrical power to one or more features that consume electrical power that are connected to or fixed to the mold tool 12. This allows a wireless transfer of power to the mold tool 12. [0043] The lower mold tool 14 is provided with magnetic material 22 as well as mold surface and/or surrounding material 11. A magnetic material 22 is formed in a manner as discussed above with regard to magnetic material 21. However, instead of a continuous body of magnetic material 21, separate individual magnetic material bodies 22 are provided. As discussed further below, other combinations of magnetic material bodies or shapes of magnetic material may be provided to optimize the heating effect at the tool. The mold tools 12 and 14 are moveable relative to each other in the direction of arrow 15.

[0044] Figure 4 shows a body of magnetic material 23 embedded in the mold tool material. The magnetic material 23 is spaced from the tool surface 16 by distance D. The distance D may be selected, prior to 3D printing, based on the mass or volume of the magnetic material, based on the number, position and power of the individual coils and based on the purpose and nature of the tool, so as to set the heat transfer and the heating effect at the surface 16.

[0045] Figure 5 shows a body of magnetic material 24 embedded in the mold tool material. The magnetic material 24 is spaced from the tool surface 16 by a distance that varies along a length of the tool surface 16. The spacing between the magnetic material 24 and the tool surface 16 may be made to vary and may be selected to achieve particular effects with the tool. For example areas that are difficult to heat may be provided with the proper heat flux, without causing problems in other regions, by selectively varying the distance, with this varying distance being determined prior to 3D printing, and this varying distance being effected via 3D printing.

[0046] Figure 6 shows a body of magnetic material 25 embedded in the mold tool material. The magnetic material 25 is spaced from the tool surface 16 by a distance that varies along a length of the tool surface 16. Further, the volume or mass of the magnetic material 25 also varies along a length of the tool surface 16. Varying the volume or mass, and also the spacing between the magnetic material 25 and the tool surface 16, may be used to achieve particular effects with the tool. The size and shape are determined prior to 3D printing, and the selected size and shape are provided via 3D printing.

[0047] Figure 7 shows a body of magnetic material 26 embedded in the mold tool material. The magnetic material 26 is spaced a constant distance from the tool surface 16. However, the volume or mass of the magnetic material 26 varies along a length of the tool surface 16. The volume or mass of the magnetic material 26 may be varied in any direction (including the width and the length directions) and may be provided in patterns or in any way as needed. Varying the volume or mass between the magnetic material 26 and the tool surface 16 may be used to achieve particular affects with the tool. The size and shape are determined prior to 3D printing, and the selected size and shape are provided via 3D printing.

[0048] Figure 8 shows a body of magnetic material 27 embedded in the mold tool material. The magnetic material 26 is spaced a constant distance from the tool surface 16 in one region and has a constant volume/mass/shape. At each end, of the body of magnetic material 27, the body of magnetic material 27 tapers, with the volume/mass decreasing based on a changing shape. In the example of Figure 8, the distance from the body of magnetic material 27 to the tool surface 16 varies at the ends. Any other variation of

volume/mass/shape of the body of magnetic material may also be provided as needed. For example, the body of magnetic material 28 in Figure 9 is spaced a constant distance from the tool surface 16, but the volume/mass/shape changes as each end. Other combinations of constant and varying shape and volume/mass may be provided based on the particular application. Further, the one or more inductive coils 52, 54, 56 and 58 may be selectively controlled to achieve a particular heating result, based on the known disposition, orientation, shape, volume and mass of the magnetic material. [0049] Figure 10 shows a body of magnetic material 2 embedded in the mold tool material. According to this embodiment, the mold tool material includes the tool material 42, which defines a tool surface 16 to be heated. The material 42 is at least partially provided as a preformed substrate with hollow channels 72. The internal ferretic or magnetic material 2 is pneumatically or magnetically drawn or pushed through these channels 72 such that the material 2 is positioned withing the material 42. The open ends of the channels 72 are closed off or sealed such that the ferretic or magnetic material 2 is embedded in the tool material 42 or held in position relative to the tool material 42 at a location adjacent to the tool material 42 and spaced away from the tool surface 16.

[0050] Figure 11 shows a body of magnetic material 2 embedded in the mold tool material. According to this embodiment the mold tool material includes the tool material 44, which defines a tool surface 16 to be heated. Additionally, a preformed base substrate 45 is provided. The internal ferretic or magnetic material 2 is 3D printed on the base 45. The tool surface material 44, defining the tool surface 16 to be heated, is 3D printed on the base, in particular, printed on the layer of ferretic or magnetic material 2. The ferretic or magnetic material 2 is shown as a single body with a constant shape. However, plural bodies may be provided and the shape, volume of material, mass of material and other aspects may be varied as noted above. The resulting tool has the ferretic or magnetic material 2 embedded in the tool material or held in position relative to the tool material at a location adjacent to the tool material and spaced away from the tool surface 16. [0051] Figure 12 shows a body of magnetic material 2 embedded in the mold tool material. According to this embodiment, the mold tool material includes the tool material 44, which defines a tool surface 16 to be heated. Additionally, a preformed base substrate 46 is provided. The preformed base substrate 46 has grooves/channels 74. These may be unfilled (filled with air or have most air removed via a vacuum process), or may be filled with a material that is heat reflective or is an insulator. The channels 74 can provide either or both a space to accommodate relative thermal expansion of the materials (as the materials will expand at different rates during heating) and a space to provide a heat directing element. The heat directing element may block or limit heat transfer in a direction away from the surface 16, by providing insulation aspects and/or may have heat reflecting properties to direct heat flux. The internal ferretic or magnetic material 2 is 3D printed on the base 45, but is not printed in the channels 74. The tool surface material 44, defining the tool surface 16 to be heated, is 3D printed on the base, in particular printed on the layer of ferretic or magnetic material 2. The ferretic or magnetic material 2 is shown as a single body with a constant shape. However, plural bodies may be provided and the shape, volume of material, mass of material and other aspects may be varied as noted above. The resulting tool has the ferretic or magnetic material 2 embedded in the tool material or held in position relative to the tool material at a location adjacent to the tool material and spaced away from the tool surface 16.

[0052] Figure 13 shows a body of magnetic material 2 embedded in the mold tool material. According to this embodiment, the mold tool material includes the tool material 48, which defines a tool surface 16 to be heated that is above other material 44. This allows the outer most material 48, which will contact the mold product (such as a foam product), to have material properties that are adapted to the molding technique. For example, the material 44 may be a polymer or some type of plastic and the material 48 may be a thin layer of aluminum alloy or some material that is suitable for the mold product, particularly suitable for contact with a release agent or contact with the mold product. The material 48 may be a fluorocarbon based polymer (such as polytetrafluoroethylene, fiuorinated polypropylene, fiuorinated ethylene, fiuorinated silicone and other fluoropolymers), particularly PTFE

(polytetrafluoroethylene). PTFE and aluminum (or aluminum alloys or other metals and metal alloys) may be provided in combination including a layer of a PTFE like element 48 on a layer of aluminum (or aluminum alloy) 44 or even discrete areas with an aluminum, aluminum alloy or metal outer surface 16 and discrete areas with a PTFE like outer surface 16. A preformed base substrate 46 is provided that may be a ceramic, a metal, polymer or a type of plastic (the same or different from material 44). The preformed base substrate 46 may again have grooves/channels 74. These may be unfilled (filled with air or have most air removed via a vacuum process), or may be filled with a material that is heat reflective or is an insulator. The channels 74 can provide either or both a space to accommodate relative thermal expansion of the materials (as the materials will expand at different rates during heating) and a space to provide a heat directing element. The heat directing element may block or limit heat transfer in a direction away from the surface 16, by providing insulation aspects and/or may have heat reflecting properties to direct heat flux. The internal ferretic or magnetic material 2 is 3D printed on the base 45, but is not printed in the channels 74. The material 44 is printed on the material 2. The tool surface material 48, defining the tool surface 16 to be heated, is 3D printed on the base, in particular printed on the layer of ferretic or magnetic material 2. In the alternative, the tool surface material 48 may be applied in other ways such as by vapor deposition or may even be a preformed layer that is applied on material 2 or material 44.

The ferretic or magnetic material 2 is shown as a single body with a constant shape. However, plural bodies may be provided and the shape, volume of material, mass of material and other aspects may be varied as noted above. The resulting tool has the ferretic or magnetic material 2 embedded in the tool material or held in position relative to the tool material at a location adjacent to the tool material and spaced away from the tool surface 16.

[0053] While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.

Claims

WHAT IS CLAIMED IS:

1. A part or tool comprising:

tool material including a tool surface material defining a tool surface to be heated; internal ferretic or magnetic material embedded in said tool material or held in position relative to said tool material at a location adjacent to said tool material and spaced away from said tool surface, said internal ferretic or magnetic material having a shape relative to said tool surface to optimize heat transfer in a direction of said tool surface, said internal ferretic or magnetic material having particles of a specific resonant frequency to give off heat upon being subjected to an alternating magnetic field with a same resonant frequency as the particles resonant frequency.

2. A part or tool according to claim 1, further comprising a heating device with an inductive coil generating the alternating magnetic field with the same resonant frequency, the inductive coil being disposed at a location spaced away from said internal ferretic or magnetic material.

3. A part or tool according to either claim 1 or 2, wherein:

said tool material comprises an insulative material; and

said internal ferretic or magnetic material is disposed in channels within said insulative material.

4. A part or tool according to claim 3, further comprising a heating device with an inductive coil generating the alternating magnetic field with the same resonant frequency, wherein:

the insulative material is a polymer; and

the inductive coil is disposed at a location spaced away from said internal ferretic or magnetic material to induce heat generation in said internal ferretic or magnetic material with the magnetic field generated outside the insulative material and passing through the insulative material without contacting the tool.

5. A part or tool according to any of the preceding claims, wherein an internal chamber is formed adjacent to said insulative material allowing for thermal expansion differentials of materials including said insulative material.

6. A part or tool according to any of the preceding claims, further comprising a heat directing element positioned relative to said tool material and relative to said internal ferretic or magnetic material to at least one of inhibit conductive heat transfer in a direction toward the outside of the tool or direct conductive heat transfer in a direction toward the outside of the tool to optimize a direction of heat transfer.

7. A part or tool according to claim 6, wherein the heat direction element comprises an empty cavity or a cavity at least partially filled with one or more of an insulator material and heat reflector material.

8. A part or tool according to any of the preceding claims, wherein:

the tool surface material defining the tool surface to be heated is 3D printed; and the internal ferretic or magnetic material is 3D printed so as to be embedded in said tool material or held in position relative to said tool material at a location adjacent to said tool material and spaced away from said tool surface and is completely contained within said tool material.

9. A part or tool according to any of the preceding claims, wherein:

the tool surface material defining the tool surface to be heated is at least partially provided as a preformed substrate; and

the internal ferretic or magnetic material is 3D printed on said preformed substrate so as to be embedded in said tool material or held in position relative to said tool material at a location adjacent to said tool material and spaced away from said tool surface.

10. A part or tool according to any of the preceding claims, wherein:

the tool further comprises a base;

the tool surface material defining the tool surface to be heated is 3D printed on said base; and

the internal ferretic or magnetic material is 3D printed on said base so as to be embedded in said tool material or held in position relative to said tool material at a location adjacent to said tool material and spaced away from said tool surface.

11. A part or tool according to any of the preceding claims, wherein: the tool material defining a tool surface to be heated is at least partially provided as a preformed substrate with hollow channels; and

the internal ferretic or magnetic material is pneumatically or magnetically drawn or pushed through said channels.

12. A part or tool according to any of the preceding claims, further comprising a receiver coil of conductive material, the receiver coil being disposed inside of the tool for inductively coupling with said inductive coil generating the alternating magnetic field, as a source coil, to inductively transfer power from the source coil to the receiver coil.

13. A part or tool system comprising:

a part or tool comprising:

tool material including a tool surface material defining a tool surface to be heated; internal ferretic or magnetic material embedded in said tool material or held in position relative to said tool material at a location adjacent to said tool material and spaced away from said tool surface, said internal ferretic or magnetic material having a shape relative to said tool surface to optimize heat transfer in a direction of said tool surface, said internal ferretic or magnetic material having particles of a specific resonant frequency to give off heat upon being subjected to the alternating magnetic field with a same resonant frequency as the particles resonant frequency; and

a heating device comprising an inductive coil generating the alternating magnetic field with the same resonant frequency, the inductive coil being disposed at a location spaced away from said internal ferretic or magnetic material.

14. A method of forming a part or tool, the method comprising the steps of:

providing tool material including a tool surface material defining a tool surface to be heated;

embedding in said tool material or holding in position in the tool material internal ferretic or magnetic material embedded in said tool material or held in position relative to said tool material at a location adjacent to said tool material and spaced away from said tool surface, said internal ferretic or magnetic material having a shape relative to said tool surface to optimize heat transfer in a direction of said tool surface, said internal ferretic or magnetic material having particles of a specific resonant frequency to give off heat upon being subjected to the alternating magnetic field with a same resonant frequency as the particles resonant frequency.

15. A method of forming a part or tool according to claim 14, further comprising providing a heating device with an inductive coil generating the alternating magnetic field with the same resonant frequency, the inductive coil being disposed at a location spaced away from said internal ferretic or magnetic material.

16. A method of forming a part or tool according to either of claims 14 and 15, wherein:

said tool material comprises an insulative material; and

17. A method of forming a part or tool according to any of claims 14, 15 or 16, further comprising providing a heating device with an inductive coil generating the alternating magnetic field with the same resonant frequency, wherein:

the insulative material is a polymer; and

18. A method of forming a part or tool according to any of claims 14, 15, 16 or 17, wherein an internal chamber is formed adjacent to said insulative material allowing for thermal expansion differentials of materials including said insulative material.

19. A method of forming a part or tool according to any of claims 14, 15, 16, 17 or 18 further comprising forming a heat directing element at a position relative to said tool material and relative to said internal ferretic or magnetic material to at least one of inhibit conductive heat transfer in a direction toward the outside of the tool or direct conductive heat transfer in a direction toward the outside of the tool to optimize a direction of heat transfer.

20. A method of forming a part or tool according to any of claims 14, 15, 16, 17, 18 or 19 wherein the heat direction element is formed with an empty cavity or a cavity at least partially filled with one or more of an insulator material and heat reflector material.

21. A method of forming a part or tool according to any of claims 14, 15, 16, 17, 18, 19 or 20, wherein:

22. A method of forming a part or tool according to any of claims 14, 15, 16, 17, 18, 19, 20 or 21, wherein:

23. A method of forming a part or tool according to any of claims 14, 15, 16, 17, 18, 19, 20, 21, or 22, wherein:

the tool further comprises a base;

24. A method of forming a part or tool according to any of claims 14, 15, 16, 17, 18, 19, 20, 21, 22, or 23, wherein:

the tool material defining a tool surface to be heated is at least partially provided as a preformed substrate with hollow channels; and the internal ferretic or magnetic material is pneumatically or magnetically drawn or pushed through said channels.

25. A method of forming a part or tool according to any of claims 14, 15, 16, 17, 18, 19, 20, 21, 22, 23 or 24, further comprising providing a receiver coil of conductive material, the receiver coil being disposed inside of the tool for inductively coupling with said inductive coil generating the alternating magnetic field, as a source coil, to inductively transfer power from the source coil to the receiver coil.

25. A method comprising forming a molded component using part or tool according to any of claims 1 - 13.