Selective laser melting (SLM) can be used to 3D print metal injection molds with complex internal cooling channels that conform to the shape of the part, allowing for shorter molding cycles. Case studies showed cycle time reductions of 10-40% for automotive and packaging parts, improving quality and decreasing costs. SLM molds offer benefits over traditional molds like improved thermal control and reduced energy usage.

1. Grobbendonk Mai 31st, 2011
Conformal cooling with SLM for plastics
Sylvain FRASSON
PEP
Injection Molding Expertise and innovation

2. Pôle Européen de Plasturgie
French Plastics Technical center
KEY 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. Additive process
Principle : Create parts directly from a CAD without tool by
Additive Process
material agglomeration (polymer, metal, ceramic…)
Advantage : New design
possibilities compared to
machining processes

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. 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. PATINNO
SLM in plastic injection molding
SLM 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. PATINNO
SLM in plastic injection molding
SLM 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. Channel examples
Possibilities of SLM tools:
SLM in injection
- Conformal cooling => cycle time
decrease ( between 10 to 40%),
- Parallel design => pressure drop
decrease

9. Case study 1 : thin-wall packaging
SLM 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. Case study 2 : Automotive Part
SLM 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. Financial and ecological results
SLM 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. 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