Toolmaker relies on additive manufacturing for complex projects

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Integrating conformal cooling channels using DMLS technology

Designers from Innomia began to develop a new tool insert cooling system, with optimised heat removal at the top of the list of priorities. The team decided to integrate conformal cooling channels, an established application using DMLS technology and one that only additive manufacturing (AM) can achieve. An Eosing M 270 system from EOS was used and the metal powder chosen was Maraging Steel 1.2709.

Diameter of the cooling channels is just 3 mm. The manufacturing process involves layer-by-layer melting of the powder by a laser programmed using 3D data from a CAD model of the mould. The Czech specialist was able to increase the hardness through post-treatment to over 50 HRc, leading to high wear resistance and low maintenance costs.

Luboš Rozkošný, CEO at Innomia explained, “The DMLS process enabled us to manufacture an extremely durable component, while at the same time successfully retain the proven advantages of AM in terms of design flexibility.

“Thanks to the conformal cooling channels integrated into the component with optimum precision, we have inexpensively resolved the main challenge of the production process.”

The temperature distribution and associated heat dissipation are now substantially more homogeneous. Since the heat leaves both the tool and the component more quickly, a water temperature of 60°C is now sufficient for cooling. The insert surface temperature does not rise beyond 90°C and the consequent fourfold reduction in temperature differential has removed the air humidity problem and reduced energy consumption.

Condensation and cavity corrosion have therefore been eliminated and the maintenance interval has been extended to between five and six weeks, saving further costs.

The uniform cooling channels work so well that the production cycle is now 17 per cent faster than previously. Component deformation is no longer a problem, raising quality and repeatability. After 370,000 cycles, total cost savings amounted to around 20,000 euros.

Pavel Strnadek, head of tool maintenance at Magna added, “There is stiff competition in the European automobile industry. That is why it is very important for us to be able to produce components to the highest quality standards at the lowest price.

“The issue of injection mould cooling was something that we have been trying to deal with for a long time. We knew how we wanted improved products to look, but realising it was just not possible using conventional manufacturing methods.

“Additive manufacturing has allowed us to make the breakthrough and we are very happy with the results at every level. Maintenance, quality of the end product, costs, heat dissipation – it has been the perfect project.”

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