Conformal cooling in the foundry or molding industry - New possibilities through metal 3D printing

The whole industry is changing:

NEW possibilities

In the foundry or in the molding shop we were always faced with the difficulty that we could not drill around the corner and therefore we could not cool where it was necessary.

For over 15 years now there has been the possibility of conformal cooling through metal 3D printing.

NEW technologies

The powder-bed-based 3-D printing permits complex conformal cooling processes due to the layer-by-layer structure. This means that almost every area of the mold or die contour can be optimally tempered, opening up completely new possibilities for part design during production.

Implementing NEW solutions

Despite the known advantages, the technology has not yet been implemented across the whole industry.

Benefit of our know-how: from the design of the cooling channels to the necessary measures in the casting process. We advise you in all relevant topics and carry out the corresponding training of your employees.

ADVANTAGES IN THE CASTING PROCESS:

REDUCTION OF SOLIDIFICATION TIME / CYCLE TIME
...through targeted heat dissipation, exactly where the heat is generated

HOMOGENEOUS, OPTIMAL MICROSTRUCTURE FORMATION
...for example, also by variothermal temperature control

AVOIDANCE OF COLD FLOW BY PARTIAL TEMPERATURE CONTROL
...no local, partial solidification due to temperature control of the material in the critical areas.

LOWER SHRINKAGE POROSITY
...optimal temperature control of the material flow.

BETTER SURFACE QUALITY
...less lubricant due to minimum quantity lubrication
...reduction of drawing marks

REDUCTION OF SCRAP AND MAINTENANCE COSTS
...avoidance of material buildup
...Reduction of fire cracks

RESOURCE-CONSERVING ADVANTAGES FOR THE CASTERS and MOLDERS

MATERIAL SAVINGS
...Material-saving geometries in the form (no longer the steel block determines the design)
...Longer service life of mould and inserts due to more even and adjustable temperature control

ENERGY
...Energy recovery through the planned dissipation of heat via closed circuits - instead of via the atmosphere.
...faster heating of the mould due to higher number of cycles

WATER
... minimum quantity spray better realizable
...less disposal and environmental impact
...cleaner working environments for casting workers - less health hazards due to cooling lubricant steam

ADVANTAGES RELATED TO COMPONENT DESIGN

GREATER DESIGN FREEDOM
...narrower geometries
...thinner-walled / lighter components - weight reduction
...better flow due to even temperature control
...Reduction of component distortion

LARGER, THINNER COMPONENTS
...more heat input in the rear areas due to shorter cycle time
...longer and better flowability

OPTIMIZED SURFACES DUE TO VARIOTHERMAL TEMPERATURE CONTROL
...variothermal temperature control allows optimum mould filling with simultaneous short cycles
...elimination of weld lines and streaks
...high-gloss surfaces (no need for expensive painting)
...moulding of microstructures

Process description Consulting and support

1. analysis phase

Analysis

process environment

water quality
temperature control units

component parts

hotspots
component errors
cycle time

2. presentation of the action plan

Presentation of the actions

Cooling medium: Process water analysis and treatment
temperature control units
Optimal cooling concepts for the shape corresponding to the component

3. construction / simulation

Component and shape design

simulations
component design
styling

4. implementation

Production of the mould insert

Choosing the right technology

3D print
Conventional methods
Production of mould inserts
Heat Treatment / Coating
post-processing

5. process installation

Measures for process insatllation

process environment
water quality

6. process establishment

Support during the process

supervision
development of process parameters
training
mold storage
mould care

Our services

Advice on tool design
Consulting component design
Tool design and simulation
Advice on optimum cooling and temperature control concepts
Staff training

My question to you:

Are you missing someone who optimizes your casting processes and supports you with the introduction of new technologies, so that you still have enough time for your daily tasks?

Our promise: that the casting processes will be successfully optimized.

We work with the best in your industry - together with over 120 years of experience in design, simulation, mold making, injection and die casting, water treatment and additive manufacturing.