Optimal mold cooling, mission impossible?
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SLM - Selective Laser Melting
100% target achieved
SLM technology:
Selective Laser Melting
Selective Laser Melting, or SLM as it is commonly referred to, is an innovative process used to produce metal parts. Unlike
traditional machine tooling involving removing shavings, SLM produces metal parts by the gradual addition of successive
layers of laser-melted powder.
MAIN ADVANTAGES
Optimising mold cooling results in:
reduced cycle time
improved aesthetic finish of the product
thanks to uniform thermoregulation
The end result is an optimised molded
part, produced at a lower cost
reduced residual stress and consequently
less warpage of the finished part
WHY EMPLOY SLM TECHNOLOGY?
HRSFlow promotes the use of, and the advantages offered by,
SLM technology in plastic molding. This involves manufacturing injection mold inserts and fittings where the cooling process is a key factor in optimising production.
The achieved goal involves total geometric freedom in the
study, design and development of cooling circuits. As a result, circuits are no longer constrained to straight lines, but
can become fully conformal waterlines for the parts involved.
Furthermore, in many cases, SLM also results in being a more
suitable alternative to highly conductive materials with poor
mechanical properties and limited resistance to wear and tear.
Example of
conformal waterlines
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WHAT CAN HRSflow OFFER?
HRSflow has the expertise to offer customers filling, packing, warpage and cooling studies. This involves cavity filling
analysis, warpage calculation and comparative cooling analysis (i.e. with both traditional cooling systems and systems
supported by SLM technology). Finally, the most suitable technical solutions to achieve optimal molding can be assessed.
Of particular interest is the fact that the conformal waterline study is always followed by fluid dynamic analysis, i.e. checks
carried out on speed, fluid flow and pressure loss in ducts in order to ensure maximum cooling efficiency and quality.
The result is an extremely precise solution that takes into full consideration the exact heat loss parameters
of the hot runner system
Comparative analysis
TRADITIONAL INSERT
SLM INSERT
HOT SPOT
HOT SPOT REMOVED
FEM analysis
SLM INSERTS: features
SLM inserts are manufactured with a lifespan equivalent to that of the mold and designed to guarantee high production run capacity. Thanks to the quality of the powder used, the mechanical properties, strength and workability
of the finished insert are virtually identical to those obtained using forged steel. In addition to aging heat treatment
(to achieve hardening equivalent to 52-54 HRC), several surface treatments can also be performed (nitriding, nickel
plating, PVD). The manufactured insert can be modified or subject to the same machining operations, such as welding
or polishing, as a traditional insert.
MAXIMUM DIMENSIONS
219
The maximum dimensions of an insert
manufactured using an SLM process are:
X 250 Y 250 Z 220 (mm)
240
Manufactured solutions
SLM technology offers the following potential solutions to manufacture the insert:
FULL SLM INSERT
Part made entirely using SLM technology. Solution
recommended in cases of reduced part size and/or
where part profile is critical.
Sector: Automotive
Hardness: 35-37HRC
Insert dimensions: 148x45x57 (mm)
Sector: Household appliances/houseware
Hardness: 48-50HRC
Insert dimensions: 54x43x52 (mm)
HYBRID SLM INSERT
Sector: Packaging
BASE material: W. No.1.2343
Hardness: 40-42HRC
SLM material: W. No.1.2709
Hardness: 35-37HRC
Insert dimensions: 178x120x92 (mm)
Sector: Technical applications
BASE material: X40Cr14
Hardness: 28-34HRC
SLM material: W. No.1.2709
Hardness: 50-52HRC
Insert dimensions: Ø50x40 (mm)
The SLM section is flawlessly welded directly onto
a base that has been forged using a traditional milling process, creating a flawless join. The forged
base can be manufactured from the same steel
used for the mold.
Solution recommended for large dimension parts
and/or where traditional solutions can be paired
with SLM solutions. Significant savings in both time
and cost.
case studies
-12%
cycle
time*
Description:
Molded material:
Part Weight:
Part thickness:
Target achieved:
Insert dimensions:
SLM insert for a reflector housing mold
ABS/PC
410 g
2 mm
reduced cycle time from 73 to 64 sec
210 x 200 x 230 (mm)
Reduced cycle time
No potential sinking
Reduced part stress
-14%
cycle
time*
Description:
Molded material:
Part weight:
Part thickness:
Target achieved:
Insert dimensions:
replacement of an existing traditional insert
with an SLM one with conformal cooling
PP
815 g
3 mm
reduced cycle time from 51 to 44 sec
215 x 47 x 80 (mm)
Reduced cycle time
No extraction problems
-15%
cycle
time*
Description:
Molded material:
Part weight:
Part thickness:
Target achieved:
Insert dimensions:
cavity insert for multicavity caps mold
HDPE
2.2 g
1.2 mm
reduced cycle time from 4.9 to 4.2 sec
ø 57 x 55 (mm)
Reduced cycle time
Optimal injection point quality
Quick colour changeover
* the cycle time depends on the whole system package: moulding machine, mould and hot runner system.
Via Piave, 4
31020 S.Polo di Piave (TV) I
Tel. +39 0422 750111
Fax. +39 0422 750301
info@hrsflow.com www.hrsflow.com
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