Fokus: PLAST Lund 4-5 maj Lunds Tekniske Högskola
Production of injection moulds using AM technology - LaserCUSING®
Martin Nielsen, Product Manager Concept-Laser
Agenda
· Who is Signcom
· Our Customers
· What is LaserCUSING®
· Examples of use
· LaserCUSING® Hybrid build style
· LaserCUSING® in research and development projects
· Flip-Cap (NeuroTemp)
· Reduction of cycletime
· Lower dimensional deviation
· Lightweight tool inserts (internal research project)
Who is Signcom
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Import, sales and service
LFP , Laser and engraving
3D print with plast and metal
Danmark, Sverige, Norge og Finland
80 employees , turn over 24 Mio EUR
Our Customers
Our Customers
What is LaserCUSING®
“3D printing in metal” SLM – Laser CUSING®
Registered trade mark of Concept Laser GmbH, from „C“ ( Concept ) and „USING“
( fusing = engl. melting )
Layer based Micro welding in “steel” powder, use of original materials, 1.2083-1.2343
Complete melting of the powder materials, therefore almost 100% density of the
components
Build rate: 3 – 100 cm3 / h (depending on the density and geometry)
What is LaserCUSING®
Hotwork steel CL 50WS (<= 54 HRC)
Closed surfaces, like microwelding
Builds layer buy layer (0.015 – 0.1 mm)
Density close to 100% (100 x enlarged)
Surface LaserCUSING® CL 50WS
Internal structure LaserCUSING® CL 50WS
What is LaserCUSING®
What is LaserCUSING®
Production of mould inserts using CAD / STL data
No conventional CNC programming required
Manufacturing of mould inserts „near net shape” over night / weekend (unattended operation)
No rough machining with CNC milling or spark erosion necessary (50-70% less electrodes)
Finishing (0,1 – 0,3 mm stock) with conventional methods required, because of surface roughness
Agenda
· Who is Signcom
· Our Customers
· What is LaserCUSING®
· Examples of use
· LaserCUSING® Hybrid build style
· LaserCUSING® in research and development projects
· Flip-Cap (NeuroTemp)
· Reduction of cycletime
· Lower dimensional deviation
· Lightweight tool inserts (internal research project)
Examples of use
Cooling channels can be designed close to the critical contours
Free design of shape / round, oval...
Cross section of cooling channel can change depending on geometry
Surface cooling possible
No stock on inserts required for rework ( shrinkage )
Examples of use
Advantage at the injection moulded plastic components:
No sink marks
Avoiding shrinkage or distorsion
No weld or knit lines
Improved part quality
Reduced cycle time (up to 50%)
Examples of use
Insert for steam iron
Material: CL 50WS
Size of insert: 44 x 64 x 63 mm
CAD-preparation / setup: 15 min.
Buildtime: 12 hours
Fitting and polishing: 13,5 hours
Examples of use
Insert for steam iron
Source: ROWENTA
Mould: 4-cavity ( 3K )
Insert: 4 x CL 50WS
Reduction of cycle time: 30%
Agenda
· Who is Signcom
· Our Customers
· What is LaserCUSING®
· Examples of use
· LaserCUSING® Hybrid build style
· LaserCUSING® in research and development projects
· Flip-Cap (NeuroTemp)
· Reduction of cycletime
· Lower dimensional deviation
· Lightweight tool inserts (internal research project)
LaserCUSING® Hybrid build style
Advantages
The portion of the core to be made with LaserCUSING ® is smaller
The simple part of the core is made by normal CNC machining rest incl. cooling channels are
produced with LaserCUSING ®
Hybrid method is the fastest and most economical method for the production of chilled inserts
LaserCUSING® Hybrid build style
The CNC machined part is fixed on ref. System like Erowa or Ststem 3R
After LaserCUSING® the top with conformal cooling the core is CNC milled ect.
LaserCUSING® Hybrid build style
Even broken parts can be fixed using LaserCUSING®
Reconstruction of old ”problem” tool, with new conformal cooling
Reparing of worn out tools or design changes
Agenda
· Who is Signcom
· Our Customers
· What is LaserCUSING®
· Examples of use
· LaserCUSING® Hybrid buildstyle
· LaserCUSING® in research and development projects
· Flip-Cap (NeuroTemp)
· Reduction of cycletime
· Lower dimensional deviation
· Lightweight tool inserts (internal research project)
Flip-Cap (project NeuroTemp)
Injection side
Ejection side
Flip Cap – conventionaly cooling design
Flip Cap – design of LaserCUSING® inserts
Comparison conventionally / LaserCUSING®
· When sampling with LaserCUSING® inserts you see the same cooling time a much lower
temperature level on the components demolded
· example: injection side surface after 10s cooling time
konventionell
LaserCUSING®
Comparison conventionally / LaserCUSING®
· With almost similar maximum temperatures with the LaserCUSING® operations, a shorter cycle
time can be achieved by 4s
after 8s conventional
after 4s LaserCUSING®
Measurement report (example)
Y
X
Location of the measuring points
Y - deviation
cooling time[s]
4
6
8
10
15
-1,6
-1,4
-1,2
-1
-0,8
Y deviation [mm]
-0,6
-0,4
LaserCUSING
gebohrt
X - deviation
cooling time [s]
4
6
8
LaserCUSING
gebohrt
10
15
-0,15
-0,1
-0,05
0
0,05
X deviation [mm]
0,1
0,15
0,2
Agenda
· Who is Signcom
· Our Customers
· What is LaserCUSING®
· Examples of use
· LaserCUSING® Hybrid buildstyle
· LaserCUSING® in research and development projects
· Flip-Cap (NeuroTemp)
· Reduction of cycletime
· Lower dimensional deviation
· Lightweight tool inserts (internal research project)
LaserCUSING® lightweight tool insert
· Idea: the temperature of the cavity completely decoupled from the tool
· Test tool plastic cup (SKZ Würzburg)
· Production of various "lightweight" tool insert with conformal cooling
LaserCUSING® lightweight tool insert
· Saving of about 50% of the volume
· Reduction of the building time
· With support structure simmilar stability as a solid material
· Support structure with a good insulating effect, thereby tempering decoupled from
the tool
Simulation of paralell LaserCUSING® cooling
LaserCUSING® lightweight tool insert
· Test Stand for testing the lightweight inserts
· Heat at 80 °C water and cooling at 20 °C water
· Variotherm tempering of engineering components
· Lower energy consumption
Agenda
The impossible has become possible….
Thank you for your attention