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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
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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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