MoldMaking Technology

JAN 2018

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Additive Manufacturing 18 MoldMaking Technology —— JANUARY 2018 By Christina Fuges 3D Robotic Deposition Advances Conformal Cooling I njection molds for automotive fascia bumpers, wheel lin- ers and instrument panels have multiple sweeping contours. During the manufacturing of a mold, the cooling design will significantly determine the cycle time. A newly patented confor- mal cooling technique has been developed that can greatly reduce cycle time by improving the cooling process while enhancing part quality, decreasing electricity and labor usage, and adhering to health and safety practices. The process uses a multilayer robotic deposition additive manufacturing technology. Six years of collaboration among welders; mechanical, elec- trical and software engineers; and graduate students from the A new conformal cooling technique has emerged, rooted in a multilayer robotic deposition technology that is capable of manufacturing near-net shape objects. Images courtesy of Productive Design Services. University of Waterloo, along with private and government- granted funding, enabled the development of an additive metals technology to create an accurate 3D object on an existing 3D contour surface. This research ultimately led to an advanced method for achieving conformal-cooled molds. Here, we'll examine the evolution of this technology by reviewing control and consistency benefits. Technology Evolution Manual TIG welding has its shortcomings, according to Pat Zaffino, managing director for Conformal Cooling These renderings illustrate coolant hole layout for a conventionally cooled core and cavity for a bumper mold (left) and a conventionally cooled cavity and a conformal-cooled core of a bumper mold. The conventionally cooled core required more than 100 holes and baffles while the conformal-cooled core required only 38 in and out water lines and no baffles. Cooling channels follow the surface contour of the core face allowing maximum coverage to evenly and quickly cool the molded part. Note that the amount of available area in the conformal-cooled core would give designers the flexibility to add lifters and slides. Conventional Cooling and Conformal Cooling Comparison

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