Conforming cooling and 3D metal printing

  • Are the increasingly complex geometry, achievement of narrow tolerances, and reduction of production costs your technological challenges too?

  • Do you want to produce prototypes without having to produce expensive tools?

New cooling technology gives us the answer; conformal cooling or cooling of the forms.

The use of conformal cooling or cooling, which is directly adapted to the contour of the product in the tool, enables a more even temperature distribution in the tool, faster heat dissipation in critical areas, a smaller input of residual stresses on the product, and consequently a greater geometric and dimensional stability of products. In addition to shorter cycles, higher productivity and lower production costs. By using a modern cooling method, we get higher quality products, whilst reducing production costs by 30 to 40 percent.

 

Modern 3D metal printing processes is a fast, simple and cost-effective way to produce tool inserts with the complex and arbitrary geometries of conformal cooling channels.

 

3D metal printing

At TECOS we are introducing another significant innovation: 3D metal printing on one of the most technologically advanced machines EOSINT M280.

TECOS stroj EOSINT 280

After receiving 3D digital data, pieces with very high quality and hardness dimensions of up to 250 x 250 x 325 mm can be manufactured in just a few hours.


At TECOS, we design and construct the form of conformal channels with advanced computer simulations of plastic injection in the Autodesk Moldflow Insight software package. We check the efficiency of cooling and shorten the cycle, and the tool inserts are manufactured using the DMLS (Direct Metal Laser Sintering) method of printing metals.

Temperatura kanali

Classical cooling

Uneven cooling is inevitable in production processes where classical cooling is used. This results in:

  • uneven temperature distribution,
  • poorer surface quality,
  • poorer dimensional stability,
  • longer cycles,
  • more waste and higher production costs.

 

konformno hlajenje 1konformno hlajenje 2

 

Conforming cooling

By using conforming cooling, tools and products are even, which means:

  • even temperature distribution and minor residual stress,
  • high surface quality,
  • better and constant dimensional stability,
  • shorter cycles,
  • less waste and savings on production costs of 30 to 40 percent.

With the assistance of advanced computer plastic injection simulations, we can also check the efficiency of conforming cooling and compare the time saved in contrast with classical cooling.

klasicno in konformno hlajenje 1

Figure 1: Difference in mould temperature between classical and conforming cooling 

klasicno in konformno hlajenje 2

 Figure 2: Difference in ejection time and 33% time saved when using conforming cooling

 

3D metal printing

At TECOS we are introducing another significant innovation: 3D metal printing on one of the most technologically advanced machines EOSINT M280.

The machine produces products from different metal materials: 

  • tool steel, 
  • aluminium, 
  • stainless steel, 
  • cobalt steel chromium, 
  • nickel steel,
  • titanium.

 

After receiving 3D digital data, pieces with very high quality and hardness dimensions of up to 250 x 250 x 325 mm can be manufactured in just a few hours.

The production of 3D metal parts with laser technology is suitable for:

  • tooling (injection tools, casting tool, tool repair);
  • industry (production of individual parts, serial production of parts, spare parts, machine parts);
  • automotive (motor sport, production of new parts, prototypes);
  • mechanical engineering (R & D parts, weight optimisation, rapid prototyping);
  • Fashion and lifestyle (glasses, jewellery and accessories, medals and pendants, coats of arms);
  • sports (sports equipment, parts for sports bikes).

 

 

A list of materials directly compatible with laser sintering (3D-printing) of metal powders with the EOSINT M 280:

  • EOS aluminium AlSi10Mg,
  • EOS cobalt-chromium MP1,
  • EOS martensitic steel MS1,
  • EOS nickel alloy HX,
  • EOS nickel alloy IN625,
  • EOS nickel alloy IN718,
  • EOS stainless steel GP1,
  • EOS stainless steel PH1,
  • EOS stainless steel 316L,
  • EOS titanium Ti64,
  • EOS titanium Ti64ELI.

 

 

3D-tisk-in-konformno-hlajenje17m 3D-tisk-in-konformno-hlajenje3m 3D-tisk-in-konformno-hlajenje4m
3D-tisk-in-konformno-hlajenje6m 3D-tisk-in-konformno-hlajenje7m 3D-tisk-in-konformno-hlajenje13m
3D-tisk-in-konformno-hlajenje14m 3D-tisk-in-konformno-hlajenje15m 3D-tisk-in-konformno-hlajenje17m

 

Why choose us?

  • more than 20 years of success stories and satisfied clients
  • a team of experts with extensive experience from the practice
  • we use leading software for injection moulding simulation Autodesk Simulation Moldflow Insight and the newest machine for 3D metal printing by leading producers EOS EOSINT M280
  • we assure fast response time
  • technical support for implementing our solutions (by telephone, by email, or in the field)
  • we are constantly introducing novelties, which is why we can offer you the latest knowledge and technology from this field.

 

 

Contact us!

MSc. Andrej Glojek, Director of Development Department
email: andrej.glojek@tecos.si
phone: +386 (0)3 490 09 22, mobile: +386 (0)31 377 787

 

Why choose TECOS?

  • Vast Experience
  • Highly Trained Staff
  • Short Response Time
  • One Contact For All Your Problems
  • State-of-the-art Equipment

Sample Project

Quickly to precise 3D model of a mill for manufacturing of replacement parts

Quickly to precise 3D model of a mill for manufacturing of replacement parts

The client had to renew a wore down rotor with knife segments for which they didn't have any documentation. With precise 3D scanning of the original and creation of functional CAD model we provided them with data for production of replacement.

Thermoplastic oil filter housing warpage prediction due to injection moulding

Thermoplastic oil filter housing warpage prediction due to injection moulding

The customer has presumed problems with excessive warpage in the stage of tool design. The material is PA66 with 30% of glass fibers. With the help of advanced injection moulding analysis we predicted the trend and values of warpage and thus successfully eliminated the problems.

Analysis of Deep Drawing Process

Analysis of Deep Drawing Process

Our client has planned a single phase deep drawing process for the presented case, however several doubts about manufacturability arose. The conducted analysis has cleared all doubts.

With Autodesk Advanced Material Exchange and Abaqus to precise results of structural FEM for fiber reinforced materials

With Autodesk Advanced Material Exchange and Abaqus to precise results of structural FEM for fiber reinforced materials

We made a comparative study between experimentaly and numerically determined strength of a fibre reinforced product, which yielded extremely good match of the results from both methods.

Prijava eseznam Tecos

Our References