GF Machining Solutions - Additive Manufacturing - GF + EOS

1. GF Machining Solutions
EDM I Milling I Laser Texturing I Tooling & Automation I Customer Service
Seamless Process
Creates The Impossible
Cooling Channel

2. When it comes to injection and blow mold tooling,
the cooler the better, and cooling channels are what
keep tooling temperatures in check. Optimized cooling
channels improve mold product quality, extend mold
tooling life and increase the efficiency of the overall
molding process.
However, there are mold shapes that can make ma-
chining optimized tool cooling channels impossible.
A perfect example would be the cylindrical shaped
molds used to produce golf balls. Optimal cooling
channels in tooling for these molds would be ones that
would mirror or conform to the cylindrical shape of
the mold cavity.
Conventional machining methods would come up
short for producing such a cooling channel pattern –
angled holes would basically be the only option. But
thanks to a multiple-machine mold tooling manufac-
turing process that combines Direct Metal Laser Sin-
In the multiple machine process chain, the DMLS sys-
tem creates the steel mold complete with conformal
cooling channels and the fixturing needed for all suc-
cessive stages of machining. This mold then moves
through the secondary portion of the process chain
that involves the high-speed milling machine and the
EDM processes, both die-sinking and wire types.
A significant advantage of DMLS is that it produces a
near-net part, in one operation, that is ready for sec-
ondary finishing. Single fixturing systems are then
used for all secondary operations to reduce manual
benchworking and ensure surface finishes are accu-
rate to within 3 to 5 microns. The process minimizes
scrap by eliminating many of the progressive opera-
tions involved in subtractive toolmaking processes
that start with a block of raw material.
For refining the DMLS part surface finish, the mold
transfers to the high-speed milling machine that cuts
the mold’s parting line for a flash-free (no leakage)
surface and finish cuts other molding surface areas.
Then the mold transfers, using the same fixturing as
used by the high-speed mill, to a die sinking EDM that
finish cuts inside mold cavities. A wire EDM cuts off
the mold fixturing, and the mold is ready for produc-
tion use.
All the operations – DMLS, high-speed milling, and
EDM – within the mold manufacturing process run
simultaneously. And, the incorporation of pallet work
holding plays a key role in helping to reduce overall
tering (DMLS), high-speed five-axis machining, and
Electrical Discharge Machining (EDM), producing con-
formal-cooled molds has become a practically seam-
less automatic process.
This manufacturing process chain is one that runs
virtually unbroken from design to finished product.
Machines used in the process are networked together
and operate from the same 3D CAD model data from
start-to-finish to increase accuracy and reduce set-
up times. Moldmakers can basically work from a 3D
model and build a mold insert around it with perfectly
located conformed cooling channels.
Conformal-cooled molds are already well established
and have enabled many high-end manufacturers to
reduce part-production cycle times by as much as 20
percent. Such DMLS-manufactured molds improve
product quality and promote longer tool life, and
the optimized cooling increases the efficiency of the
whole molding process as well. For large-volume pro-
duction, the resulting time and cost savings—as well
as carbon footprint reduction—are considerable.
There are many documented success stories from
moldmakers benefitting by using DMLS to create
molds that employ conformal cooling channels. But
partnered with high-speed milling and EDM within one
manufacturing chain, allows DMLS to be more easily
implemented, especially by those manufacturers run-
ning high-volume injection and blow molding opera-
tions.
process time.
Instead of manually mounting parts, the DMLS ma-
chine builds “pallets” out of steel powder as part of
the mold insert. By doing so, parts are positioned ac-
curately as they effortlessly transfer from the high-
speed milling machine to the EDMs. After use as work
holding, these pallets are simply cut off at the end of
the process
About GF Machining Solutions
GF Machining Solutions is the North American lead-
ing supplier of laser ablation centers, wire EDM, CNC
and manual diesinking systems and high speed/per-
formance and 5-axis CNC milling machines. For more
information on the company’s products and services,
contact Gisbert Ledvon, GF Machining Solutions, 560
Bond St., Lincolnshire, IL 60069-4224, Tel: 1-800-CTC-
1EDM. Gisbert.Ledvon@georgfischer.com, Fax: 847-
913-5340, or visit http://www.gfms.com/us.
About EOS
EOS was founded in 1989 and is today the world-lead-
ing manufacturer of laser-sintering systems. La-
ser-sintering is the key technology for e-Manufactur-
ing, the fast, flexible and cost-effective production of
products, patterns and tools. The technology man-
ufactures parts for every phase of the product life
cycle, directly from electronic data. Laser-sintering
accelerates product development and optimizes pro-
duction processes. EOS completed its business year
2008/2009 with revenues of 60 million Euros. The
company employs 300 people worldwide, 250 of them
in Krailling near Munich, Germany. For more informa-
tion visit www.eos.info.
Example of conformal cooling chanels in a mold

3. GF Machining Solutions
Your Contact
GF Machining Solutions
560 Bond St.
Lincolnshire, IL 60069
USA
Website: www.gfms.com/us
Phone: 847.913.5300
Email: info.gfms.us@georgfischer.com
Facebook: facebook.com/gfmachiningsolutions
Twitter: twitter.com/gfms_us
Youtube: youtube.com/agiecharmilles