PEP - Sylvian Frasson

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PEP - Sylvian Frasson

  1. 1. Grobbendonk Mai 31st, 2011 Conformal cooling with SLM for plastics Sylvain FRASSONPEPInjection Molding Expertise and innovation
  2. 2. 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
  3. 3. 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
  4. 4. 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
  5. 5. 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
  6. 6. 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
  7. 7. 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
  8. 8. Channel examples Possibilities of SLM tools:SLM in injection - Conformal cooling => cycle time decrease ( between 10 to 40%), - Parallel design => pressure drop decrease
  9. 9. 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
  10. 10. 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
  11. 11. 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.
  12. 12. 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

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