Hybrid tool optimises injection molding Showcase

Injection mold with internal conformal cooling additively placed by selective laser melting on the tool base. Reduction of cycle time by 60%.

Description

The company Michael Dewald Kunststoffverarbeitung GmbH in Tettnang (Germany) is an advanced injection molding manufacturer with customer focus in Southern Germany and Switzerland. The company has worked in various areas of mechanical engineering, automotive and electrical engineering. Dewald currently operates 32 injection molding machines and provides all molds within their own toolmaking.

The aim of this project was to replace...

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The company Michael Dewald Kunststoffverarbeitung GmbH in Tettnang (Germany) is an advanced injection molding manufacturer with customer focus in Southern Germany and Switzerland. The company has worked in various areas of mechanical engineering, automotive and electrical engineering. Dewald currently operates 32 injection molding machines and provides all molds within their own toolmaking.

The aim of this project was to replace the existing injection mold for the handle of a bicycle carrier by an additive-crafted tool with internal conformal cooling to reduce the cycle time. Furthermore, the existing conventionally produced tool base plate should be used to limit the additive manufacturing to a minimum.

Through a sophisticated hybrid design the injection mold was optimized with conformal cooling and the cooling was simulated successfully. Was followed by the additive manufacturing by selective laser melting on the base plate. The post processing was made by conventional milling and polishing.

By conformal cooling within the double tool, the cycle time can be reduced by 60% from 55 seconds to 22 seconds. Thus, increased production costs for the tool  by the additive manufacturing can be easily compensated.

This showcase shows:

Product of customer

Major benefits achieved

Better performance (e.g. fluid dynamics, heat-exchange)

Field of innovation

Support parts

Customer

Michael Dewald Kunststoffverarbeitung GmbH in Tettnang (Germany)

Customer industry

Toolmaking
Provider

ZHAW Zürcher Hochschule für Angewandte Wissenschaften, ZPP Zentrum für Produkt- und Prozessentwicklung

Supplier position in the value chain

R&D + Organisations
Suppliers + Vendors
Processors + Service providers
Manufacturer (OEM)
Technologies and materials
See this showcase

ZHAW Zürcher Hochschule für Angewandte Wissenschaften, ZPP Zentrum für Produkt- und Prozessentwicklung will display this showcase at the following exhibition:

AM Expo 2016
20. and 21. September 2016, Messe Luzern, Switzerland
Halle 02 / Booth C 2086