This document discusses selective laser melting (SLM) technology for manufacturing conformal cooling inserts for injection molds. It describes how SLM allows for complex internal channel geometries to optimize cooling. Several case studies show how SLM inserts improved temperature uniformity, reduced cycle times, and eliminated part warping compared to traditional drilled inserts. Mold designers can leverage SLM to integrate optimized cooling at the design phase for maximum benefits.
Selecting the "perfect" PCB surface finish can be a daunting task! Take a look at this quick introduction and ensure you and your company make an informed decision.
Selecting the "perfect" PCB surface finish can be a daunting task! Take a look at this quick introduction and ensure you and your company make an informed decision.
Public sector innovation: Increasing the capacity for change and improvement ...OECD Governance
This presentation was made by Madeleine Siösteen Thiel, Sweden, at the 4th meeting of the Joint DELSA/GOV-SBO Network on Fiscal Sustainability of Health Systems, held in Paris on 16-17 February 2015.
Laura Overton on Planning for success (e-learning) | www.brightwave.co.ukBrightwave Group
Laura Overton's slides from Brightwave and Sky's 'Time to make a difference - e-learning strategies to support business' event. Originally held on 23rd June 2011.
See more slides and download the event review here:
http://www.brightwave.co.uk/events/time-to-make-a-difference-e-learning-strategies-to-support-business-event
kasina: Costs of Compensation - Sales & National Accounts 2009kasina
kasina's 2009 study of Sales and National Accounts compensation; key findings on trends, and recommendations for asset managers to improve their compensation practices
Eye protection ppe toolbox talk trainingAlan Bassett
Much of the work we carry out day to day present’s significant hazards with respect to your eyes. Your eyes can be harmed in many ways from chemical slashes, welding flashes and inclusions of metallic particles.
Even ‘minor’ eye injuries can cause life-long vision problems and suffering a simple scratch from sawdust, cement, or drywall can cause corneal erosion that is recurrently painful...
Solving performance problems in MySQL without denormalizationdmcfarlane
As operational database schemas become complex, users resort to denormalization to handle performance issues. This includes a range of techniques from materialized views to using MySQL as a key-value store for blobs containing full objects. While denormalization solves immediate bottlenecks, it comes at a hefty price. In this presentation Ari will explore common denormalization approaches and tradeoffs using real world examples. He will then present a solution under development at Akiban Technologies to alleviate these same problems much more efficiently, and allow users to get the best of both worlds.
Sleeping Giant Build is a community based organization partnering with local businesses, religious organizations, civic groups, individuals and our partner families to eliminate poverty housing in the greater New Haven area.
Saturn Electronics Corporation is a Top 10 U.S. domestic bare printed circuit board manufacturer providing low-to-high volume production as well as complex prototypes and advanced technologies such as blind and buried vias, heavy copper, PTFE hybrids for RFMW and metal core for LED thermal management.
Increasing die life, reducing rejections by the use of japanese cold welding ...Srikar Shenoy
1. Die, mould and tool wear are major reasons for production downtime and increased costs in most industries. Apart from using suitable alloy steels for making dies, a few effective treatments like nitriding, PVD & CVD can be administered to increase die life. Such treatments are not feasible for all metal forming units. Carbide coating to protect only the wear-prone areas of dies using Japanese cold-welding technology is a practical and economical technique that has proven to increase die life. This technique, though similar to welding, does not need pre and post-weld heat treatment and skilled labour. The process does not emit smoke. It can also be carried out on the die or tool without unloading it from the casting press or such equipment, without need of a weld shop.
2. Die spray units are used to effectively spray lubricant on the dies. During the pressure die casting process, it is mandatory to keep die and plunger well lubricated. Die protective coating cum lubricant is used to achieve these objectives. Until recently, pressure feed tanks have been used to spray-lubricate dies. However, these conventional pressure-feed tanks are proving to be a hazard on the shop floor. Pressurised equipments on shop floor always pose a risk of explosion. They also cause production downtime during re-filling. Better alternatives are now available for dispensing die lubricants.
Public sector innovation: Increasing the capacity for change and improvement ...OECD Governance
This presentation was made by Madeleine Siösteen Thiel, Sweden, at the 4th meeting of the Joint DELSA/GOV-SBO Network on Fiscal Sustainability of Health Systems, held in Paris on 16-17 February 2015.
Laura Overton on Planning for success (e-learning) | www.brightwave.co.ukBrightwave Group
Laura Overton's slides from Brightwave and Sky's 'Time to make a difference - e-learning strategies to support business' event. Originally held on 23rd June 2011.
See more slides and download the event review here:
http://www.brightwave.co.uk/events/time-to-make-a-difference-e-learning-strategies-to-support-business-event
kasina: Costs of Compensation - Sales & National Accounts 2009kasina
kasina's 2009 study of Sales and National Accounts compensation; key findings on trends, and recommendations for asset managers to improve their compensation practices
Eye protection ppe toolbox talk trainingAlan Bassett
Much of the work we carry out day to day present’s significant hazards with respect to your eyes. Your eyes can be harmed in many ways from chemical slashes, welding flashes and inclusions of metallic particles.
Even ‘minor’ eye injuries can cause life-long vision problems and suffering a simple scratch from sawdust, cement, or drywall can cause corneal erosion that is recurrently painful...
Solving performance problems in MySQL without denormalizationdmcfarlane
As operational database schemas become complex, users resort to denormalization to handle performance issues. This includes a range of techniques from materialized views to using MySQL as a key-value store for blobs containing full objects. While denormalization solves immediate bottlenecks, it comes at a hefty price. In this presentation Ari will explore common denormalization approaches and tradeoffs using real world examples. He will then present a solution under development at Akiban Technologies to alleviate these same problems much more efficiently, and allow users to get the best of both worlds.
Sleeping Giant Build is a community based organization partnering with local businesses, religious organizations, civic groups, individuals and our partner families to eliminate poverty housing in the greater New Haven area.
Saturn Electronics Corporation is a Top 10 U.S. domestic bare printed circuit board manufacturer providing low-to-high volume production as well as complex prototypes and advanced technologies such as blind and buried vias, heavy copper, PTFE hybrids for RFMW and metal core for LED thermal management.
Increasing die life, reducing rejections by the use of japanese cold welding ...Srikar Shenoy
1. Die, mould and tool wear are major reasons for production downtime and increased costs in most industries. Apart from using suitable alloy steels for making dies, a few effective treatments like nitriding, PVD & CVD can be administered to increase die life. Such treatments are not feasible for all metal forming units. Carbide coating to protect only the wear-prone areas of dies using Japanese cold-welding technology is a practical and economical technique that has proven to increase die life. This technique, though similar to welding, does not need pre and post-weld heat treatment and skilled labour. The process does not emit smoke. It can also be carried out on the die or tool without unloading it from the casting press or such equipment, without need of a weld shop.
2. Die spray units are used to effectively spray lubricant on the dies. During the pressure die casting process, it is mandatory to keep die and plunger well lubricated. Die protective coating cum lubricant is used to achieve these objectives. Until recently, pressure feed tanks have been used to spray-lubricate dies. However, these conventional pressure-feed tanks are proving to be a hazard on the shop floor. Pressurised equipments on shop floor always pose a risk of explosion. They also cause production downtime during re-filling. Better alternatives are now available for dispensing die lubricants.
LaserBond™ achieves a welded or metallurgical bond with minimal, precisely controlled heat input provided by an optimized laser beam. Temperature sensitive components and materials, such as hardened shafts, gears etc, can be repaired with minimal risk of distortion or other undesirable heat effects. The metallurgical bond allows LaserBond™ applied layers to be used in high impact, heavily loaded/stressed situations with no risk of spalling or separation of the overlay. The controlled energy minimizes the undesirable thermal decomposition of hard phases such as carbides, resulting in optimum wear resistance. Due to the extremely low dilution with the substrate, high specification materials can be applied in a thin layer with corrosion and wear resistant surfaces as thin as 0.3mm possible. Thick overlays for significant repairs of up to 20mm can also be applied in multiple passes. Heat affected zones are minimized and the stress related cracking inherent in welded or PTA applied hard facing is generally eliminated. Standard LaserBond™ overlay options include Tungsten Carbide, Stainless Steels, Nickel alloys such as Inconel, and Cobalt alloys such as Stellite1. Other materials can be applied on request.
The High Pressure High Velocity Oxy-Fuel process applies coating material at supersonic velocities, resulting in surfaces of the highest possible quality and performance.
HP HVOF coatings are very dense, very well bonded, and free of the oxides and tensile stresses typically found in coatings produced with other thermal spray processes. Consequently, they perform better in most service environments. HP HVOF wear resistant coatings are being adopted globally as an environmentally friendly, and technically superior, alternative to Chrome plating on components such as aircraft landing gear. Surfaces combining resistance to corrosion and wear are also routinely applied by HP HVOF. LaserBond™ approved HP HVOF coatings include Tungsten Carbide, Chrome Carbide, Nickel based alloys (e.g. Inconel 625 and 718), Cobalt alloys such as Stellite1, stainless steels and copper based alloys.
Ajith Ranasinghe | Sales Engineer
LaserBond Ltd
2/57 Anderson Road, Smeaton Grange NSW 2567
| m:+61417618512 | t: +612 4631 4500 | f: +612 4631 4555
ajithr@laserbond.com.au
Our main goal is to cover our customer needs in terms of quality, performance and product lifetime. How important are the treatments and processes that our canopies suffer? Check it in this technical article.
Cirexx is a small business specializing in Time Critical Design, Fabrication and Assembly of Rigid-Flex, RF, Flex, and Hybrid printed circuit boards. We do quick turn, high-quality fabrication and assembly at one location and are MIL-Spec 31032 and ITAR certified.
2. SLM : How the Machine works
Laser beam
Recoater
Collector bin
Dispenser
Part on
process
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3. SLM FOR INSERTS WITH CONFORMAL COOLING
Conformal cooling channels means:
channels shaped according to molding surface (impossible to realize with drilling technology),
short and constant distance between channel wall and molding surface,
any channel cross section geometry is possible (elliptical, squared, etc…),
surface cooling possibility.
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4. SURFACE COOLING
Surface cooling means perfectly uniform temperature on molding surface
Advantages: Disadvantages:
- uniform temperature on molding surface, - good water quality required to avoid channel obstruction
- no warpage due to uneven cooling time,
- shortest achievable cycle time.
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5. CHANNEL DESIGN AND FLUIDODYNAMIC SIMULATION
Fluid dynamic simulation for cooling channels design optimization:
flow rate balancing in cooling channel ramification,
pressure losses control,
velocity increase in areas critical for incrustation.
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6. CHANNEL SIZE AND WALL ROUGHNESS
Smaller channel diameter (starting from Ø0.5mm) :
permits to cool critical areas that standard technology cannot reach,
needs to use de-mineralized and clean water to avoid risk of channel obstruction due to
calcareous incrustation.
Channel wall nickel coating is possible in order to avoid:
calcareous incrustation,
oxidation.
Channel wall roughness is approximately 40 µm.
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7. HYBRID BUILDSTYLE INSERT
Hybrid insert obtained by laser melting on a
preformed milled base:
laser melting only for the insert part where
conformal channels cannot be machined with
standard drilling;
lower manufacturing time and costs;
SLM part
Preformed milled
base
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8. HYBRID BUILDSTYLE INSERT
In hybrid inserts, locating pins and no stock in the bottom base allow fast clamping for
machine finishing.
Stock to
remove
Locating
pins
Finished
bottom base
Threaded
holes
Locating
pins
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9. HYBRID BUILDSTYLE INSERT
Test have been performed to prove the optimal adhesion between SLM part and base
manufactured from forged steel.
Ultimate tensile strength 1050 MPa up to 1200MPa according to base material.
Base
Surface adhesion
between SLM and base
SLM part
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10. HYBRID BUILDSTYLE INSERT
Tested base materials:
1.2311 / 12
1.2343 hardened at 48 HRc
AISI 420
Toolox 40
Adhesion line between SLM and machined base doesn’t affect aesthetic of the molded
part
As built Finishing machined Adhesion line
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11. SELECTIVE LASER MELTED STRUCTURE
Parts manufactured with SLM technology
have the same mechanical properties
as those machined from forged steel
Laser melting means fully dense part!
Laser stripes
100 x enlargement of an SLM surface part
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12. STEEL FOR SLM Injection molding Applications
Maraging 300 (W.1.2709)
Characteristics:
same mechanical properties as W.1.2311 or W.1.2343 according to heat treatment,
low stresses and deformation after precipitation hardening (much lower than quenching),
less brittle than W.1.2343 at same hardness,
good standing wear and tear,
nitriding, nicheling, PVD coating possible,
weldable,
easily machinable with milling machine, lathe and spark erosion machine (EDM),
texture possible.
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13. STEEL FOR SLM Injection molding Applications
Maraging 300 (W.1.2709)
Mechanical properties:
“As built”: After precipitation hardening:
Hardness: 35-37 HRc Hardness: from 48 HRc up to 54 HRc
Yield strenght: 1000 MPa Yield stress: from 1400 MPa up to 1900 MPa
High gloss polishing:
gloss polishing possible,
light pitting defects may affect transparent aesthetical parts quality
tests are going on to find special coating and / or remove inclusion forming during building
process
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14. INGLASS HRS DESIGN CAPABILITIES for SLM Inserts
Cutting plane SLM
Forged base
Required data: 1. Cutting plane positioning 2. Channel design on:
insert 3D file preformed base
molding surface SLM part
identification
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15. INGLASS HRS DESIGN CAPABILITIES for SLM Inserts
3. Fluidodynamics simulations 4. Base machining and SLM 5. Thermal treatment and / or
manufacturing coating
6. Insert with stock shipping
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16. SLM WARRANTY AND DELIVERY TIME
SLM inserts warranty runs for the entire mold life
Delivery time may vary between 2 and 4 weeks according to geometry
complexity and required heat treatment or coating
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17. MOLD COOLING OPTIMIZATION SUPPORT
Mold cooling phase:
represents 60-75% of the entire cycle time
affects aesthetic of the part
controls warpage of the part
INglass offers a cooling optimization support in order to:
reduce / optimize cycle time
improve aesthetic of the part
control the warpage
cost reduction
parts better quality
scrap reduction
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18. MORE THAN 20 YEARS KNOW HOW IN MOLDMAKING AND TRY
OUTS
1. Know how from:
Mold design
Molding process
Hot runner design
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19. TOOLS AND SKILLS FOR COOLING OPTIMIZATION
2. Mold Flow and EFDLab software:
EFDLab
Mold Flow (filling, packing, cooling, (for thermo-fluidodynamics simulation)
warpage analysis and fiber orientation)
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20. TOOLS AND SKILLS FOR COOLING OPTIMIZATION
3. Standard technology tools:
circuit modification by double thread screw barblers,
added drilled holes, etc…
high thermal conductivity inserts,
isopipes.
isopipes
adding drilled channels
Add cooling lines fountains
Ø14.27 closer to
Add baffle molding surfaces
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21. TOOLS AND SKILLS FOR COOLING OPTIMIZATION
4. SLM technology for inserts with conformal cooling channels
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22. MOLD COOLING ENGINEERING DURING MOLD DESIGN PHASE
Case 1: engineering during mold design phase
Customer provides mold 3D files including cooling lines design
INglass offers:
Mold Flow simulations including filling, packing, cooling and warpage to check correct
gates location, hot spots (critical areas for cooling), deformation of the part, etc..
mold design and cooling system modifications (gate location, new cooling lines design,
SLM conformal channels insert, etc…)
new Mold Flow analysis to check modification effectiveness
Time required: 10 working days
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23. MOLD COOLING OPTIMIZATION AFTER PRODUCTION START
Case 2: mold cooling engineering to solve cooling problems faced during
production (high cycle time and / or part deformation)
problems analysis and identification of a solution through standard technology or SLM
conformal channel inserts
if required Mold Flow cooling analysis to prove the modification effectiveness and
identify cycle time reduction
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24. COOLING IN DESIGN PHASE ADVANTAGES
Cooling optimization during design phase rather than modification during
production ensures:
shorter design time for cooling engineering support during design phase (10 working
days),
no costs for cooling system modification (drilling new cooling channels, machinery of
SLM insert pocket, etc…),
no production stop for mold modification,
no waste of time for extra tryouts,
scrap reduction.
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25. REAL CASE n°1 : Automotive air conditioning component
Mold temperature
Standard insert
Hot spot
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26. REAL CASE n°1 : Automotive air conditioning component
Mold temperature
SLM insert
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27. REAL CASE n°1 : Automotive air conditioning component
Standard insert SLM insert
Standard insert replaced by
SLM insert
Cycle time Size:
reduction: 5 230 x 230 x 50
seconds mm
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28. REAL CASE n°2 : Slide for Automotive Lens
Mold temperature
Standard insert
Hot spot
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29. REAL CASE n°2 : Slide for Automotive Lens
Mold temperature
SLM insert
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30. REAL CASE n°2 : Slide for Automotive Lens
Standard slide SLM slide
Standard insert
replaced by SLM
insert
Warpage
problem fully
solved
Size:
230 x 230 x
80 mm
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31. REAL CASE n°3 : Insert for air conditioning component
SLM insert choice
at design phase
Optimized
cooling
Size:
80 x 60 x 210
mm
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32. REAL CASE n°4 : Insert for engine cover
SLM insert choice
at design phase
Optimized
cooling
Size:
160 x 160 x 200
mm
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33. REAL CASE n°5 : Insert for automotive lighting housing
Bad cooling area
=> - high cycle
time - bad
ejection
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34. REAL CASE n°5 : Insert for automotive lighting housing
Standard insert
replaced by SLM insert
Cycle time reduction: 9
seconds
Size:
120 x 180 x 25
mm Warpage problem fully
solved
Rib thickness
5.5mm
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35. REAL CASE n°6 : Insert for automotive lighting housing
SLM insert chioce
at design phase
Optimized
cooling
Size:
80 x 30 x 70
mm
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36. REAL CASE n°7 : Two step element for Truck
3D part with 4 Moldmax inserts on 3D part with conformal channel
bosses (hot spots affecting cycle time) SLM inserts on critical bosses
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37. REAL CASE n°7 : Two step element for Truck
Time to freeze Time to freeze
ax
d M ts
o l er
M s
in
102.9 s 109.7 s 91.9 s 105.4 s
37 R&D Technologies REV 1.0
38. REAL CASE n°7 : Two step element for Truck
Time to freeze Time to freeze
erts
i ns
M
SL
89.2 s 102.0 s 79.6 s 88.8 s
- - 7.5s - -
13.7s 12.3s 16.6s
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39. REAL CASE n°8 : SLM inserts for gate conditioning 16 cavity mold
Cooling circuit around
the gate
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