Award-winning tool shop uses laser fusion for cooling inserts

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Issue of costs and speed in mould making

"Time is money," according to the common saying. But above all, short development times produce enormous time pressures for product developers, mould makers and processors. The Laser Cusing metal additive manufacturing process makes it possible to fuse powder materials made from original material layer by layer. Today, hardness levels of up to 52 HRC are achieved, depending on the material. In particular, when manufacturing the mould insert, conventional technology entails personnel costs because the turning and milling process has to be continuously monitored. This is different with the laser fusing of metals: Once the parameters have been chosen, the Laser Cusing machine is said to run without an operator 24 hours a day. In the case of hybrid parts, the mould maker saves both time and costs: The formative residual geometry – including the remaining cooling-channel design – can be "fused" onto a prefabricated basic body with predrilled feed and drain holes for the cooling. With such a mixed type of construction, this procedure has, in many cases, already proven to be the fastest and most economical method. The general rule is that generative technology produces a faster result – and is less expensive.

According to Fassnacht, “With the generative metal additive manufacturing process, we are able to save time in the design and manufacturing phase, and it is also easier to incorporate requests for changes to be made.” Not only does the shop make the inserts for its own tooling, the company also supplies the components to other mould makers. “This topic will become more important if we also think about hybrid parts where formative residual geometries are ‘fused’ onto prefabricated basic bodies by means of Laser Cusing. So, you simply have completely different possibilities at your disposal.”

The technology also performs well in inserts for round parts

According to the experiences gained at Fassnacht, round parts in particular are very suitable for inserts based on laser fusing. Round mould inserts can be manufactured much more cheaply with the method. This is because with integration of conformal cooling there is no need for any recesses and grooves for O-rings. It is therefore easier to construct the insert. As a consequence, the outlays on design, manufacturing and reworking is reduced and the costs are, too. At Fassnacht, the “generative approach” with a laser is very important in design and mould making.

Debunking reports of blocked temperature control channels

When asked about allegations that conformal cooling channels tend to become blocked, the shop manager was blunt in his disbelief: “You have probably got more of a chance of encountering a yeti. In 2012, we supplied the 1,000th Laser Cusing insert with conformal cooling. I have never experienced this ‘problem’. It is probably just a myth. In all seriousness, you must look at the following clearly: Conformal cooling speeds up the physics in the mould. Shorter cycles mean greater added value. Period.”

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