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PEP - Sylvian Frasson
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PEP - Sylvian Frasson

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PEP - Sylvian Frasson PEP - Sylvian Frasson Presentation Transcript

  • Grobbendonk Mai 31st, 2011 Conformal cooling with SLM for plastics Sylvain FRASSONPEPInjection Molding Expertise and innovation
  • Pôle Européen de Plasturgie French Plastics Technical centerKEY FIGURES Injection molding expertise – Thermoplastics – Research&Development – Eco-design – Technology transfer Created in : 1989 Employees : 55 Turnover : 5 500 K€ (2010) Location : Oyonnax (01), France Web: www.poleplasturgie.com Certified ISO 9001-V2008
  • Additive process Principle : Create parts directly from a CAD without tool byAdditive Process material agglomeration (polymer, metal, ceramic…) Advantage : New design possibilities compared to machining processes
  • Processes and some application examples AdditiveProcess Stereolithography (SLA) : Prototyping, concept models…Additive Process Prometal – Metal casting 3D System – Jewellery 3D printing : Architecture, metal casting… Zcorp – Architecture Selective Laser Sintering/Melting (SLS/SLM) : Air plenum parts, orthesis, prothesis… PHENIX – Prothesis EOS – Prothesis
  • Metal Selective Laser Melting (SLM or DMLS)Additive Process Principle Selective Laser Melting: - Spread of one powder layer - Selective laser interaction - Down feed of one layer thickness - New spread of powder - Melting of the following layer… Thermal or mechanical post- treatment possibilities Standard values : - Building volume : 250x250x300mm - Accuracy : +/- 0.05mm - Layer thickness: 40 µm Standard materials : Maraging Steel (1.2709) Properties: - Density 99.8% (usual value for this kind of material) - Ultimate tensile strength 1950MPa after age-hardening - Hardness 50-54HRc after age-hardening - maximum operating temperature 400 C
  • PATINNO SLM in plastic injection moldingSLM in injection Interest : complex internal cooling channel shape near the injected surface, concept called « conformal cooling ». Some application examples : Technical automotive injected part, Cosmetics packaging (vial, closure…), High speed injection packaging, Electrical devices, Medical parts, … SLM growth in tooling application: 2007 2008 2009 2010 PEP Nbr of 6 15 50 80 applications
  • PATINNO SLM in plastic injection moldingSLM in injection Some applications have been made for the automotive, cosmetic, medical, packaging industrie, but they are confidential Steps to create a SLM injection tool: UFFO Insert Channel Fluidic Building of the Insert CAD Machining assembly in Injection Design simulation SLM part mold
  • Channel examples Possibilities of SLM tools:SLM in injection - Conformal cooling => cycle time decrease ( between 10 to 40%), - Parallel design => pressure drop decrease
  • Case study 1 : thin-wall packagingSLM in injection Description : - Mold Maker : SECO - Injected material : PP - Expected cycle time : 4s - Tool Hardness after thermal treatment 52 HRc - Mirror finish by polishing Results : - Cycle time 3,9s - No Copper-beryllium insert
  • Case study 2 : Automotive PartSLM in injection Description : - Mold Maker : PERNOUD - Injected material : PA 6.6 - Expected cycle time 50s - Real time cycle without SLM tool : 70s Results : - Cycle time 43s => 35% decrease of the cycle time - Better thermal homogeneity => less deformation, better surface quality : less scraps and no more need to paint the part
  • Financial and ecological resultsSLM in injection Financial results: example - Tool extra cost ~ 25 000€, - Molding cycle time savings ~30% : 50 000€/year - Other savings : reduced scraps, faster delivery time to customer, faster mold start-up, - ROI : 6 months , - Hurdle : investment costs for the purchasing team, and productivity for the plants. Ecological results: - Conformal cooling improves tool energy efficiency , reduces scraps, and in some cases eliminates the painting process.
  • Pôle Européen de Plasturgie Thanks for your attention, Alexis Bricout alexis.bricout@poleplasturgie.com 2 rue Pierre et Marie Curie BP 1204 – Bellignat 01117 OYONNAX CEDEX • FRANCE Tel : +33 (0)4 74 81 92 60 Fax : +33 (0)4 74 81 92 61 Web: www.poleplasturgie.com mail : info@poleplasturgie.com