Metal additive manufacturing to gain ground in die and mould

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ETMM: That’s during the bidding process. But this changes later, right?

Niavas: What sometimes happens then, for example in the car industry, is that the project needs further optimisation loops to meet the requirements of customers, which can require further resources and result in additional delays. These improvement cycles provide a real chance to implement conformal cooling solutions and business opportunities for the tooling solution providers. But with this fragmentation of the market, at the moment it is not that interesting for mould makers to acquire the system as it is still not fully perceived as a reference technology for tooling. Our goal is to change this perception by improving the visibility of the EOS technology on the customer side.

ETMM: What else is holding shops back?

Niavas: Many mould makers still associate risk with this technology. As a mould maker, you only want products or solutions that are well-known, that have been on the market for a long time, are established and for which historical and statistical data are available. Reliability is key, too, since mould makers need to deliver a warranty on the lifetime moulds. Even if a shop has been familiar with the technology for five years, it still needs a longer learning curve to fully master it. Basically, a mould maker needs to go back to review and update an important part of the know-how acquired over the years to be able to tap into the full potential of additive manufacturing. The freedom of design, for example, can lead to higher productivity and insert quality. You need to learn first how to achieve the right design. So, to make life easier, a mould maker does not want to purchase the equipment himself and take control of the technology. Instead, he often prefers to rely on external service, always with an eye on risk.

ETMM: Why use conformal inserts?

Niavas: When you are making cooling channels with conventional methods – drilling, using baffles, etc. – much effort is needed to find a good compromise for the productivity of your tool. With this technology, if you decide to put the channel 3mm away from the cavity or on top of a very long core (when structurally acceptable), our system will print it! It’s no longer about looking for a compromise since you can make the design you have been thinking about.

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Metal additive manufacturing to gain ground in die and mould