Moldfusion™ "Art to Part" Metal Printing Turns CAD Creativity Into 3D Molds
MoldFusion™
3D metal printing builds molds from the inside out, layer on layer, to enable
creation of "impossible" internal features and geometries, along with
near net shape cavities and mold faces for minimal machining and finishing. The
breakthrough tooling technology meets molder needs for rapid tooling and shorter
lead times, while freeing design creativity for applications such as conformal
cooling and thermal cycling.
Exclusively available from a technology partnership between D-M-E Company and the ProMetal™ Division of Extrude Hone Corporation, MoldFusion adapts stereolithography techniques to print layer-by-layer with powder tool steel in a binder matrix. Invented at MIT, the MoldFusion process creates near net shape 3D structures from 3D CAD models.
MoldFusion is not a replacement for conventional tooling, but a solution for applications that are not practical or possible using conventional metalworking. The CNC controlled additive forming process enables unprecedented external and internal geometric flexibility. Benefits of the MoldFusion technology include:
•
Off-loading of low-value rough machining time on high complexity jobs
• Rapid creation of production tooling for prototypes or short runs in less
time
• Cycle time reductions of 20-35% through conformal cooling water lines
• Improved part dimension control with advanced cooling designs
• Thermal insulation of areas of mold temperature difference
• Dynamic cycling of mold temperature with the injection molding cycle
MoldFusion builds what customers can imagine. Customer CAD data is supplied to D-M-E, reviewed for application effectiveness, and electronically communicated to the ProMetal Division of Extrude Hone. The ProMetal 3D printing process prints successive 2D "slices" through deposition of powder tool steel in a binder matrix. Molds are built up layer-by-layer to near net shape. Upon completion of the stereolithography, the "green" part is loaded into a sintering furnace that fuses a tool steel skeleton of 60% density and burns off the binder. A second furnace cycle infiltrates the part with molten bronze via capillary action to full density.
The
near net shape part is then ready for final machining by the customer. All
common finishing processes are possible with MoldFusion products, including
turning, milling, grinding, EDM, and polishing. Also, coatings to enhance wear
and chemical resistance, such as nickel and chrome plating, work well on
MoldFusion inserts.
The
process can create complex geometry structures up to 12" (304.8mm) in
length and width and 10" (250mm) in height.
MoldFusion
is particularly suited to conformal cooling of mold inserts. It allows designers
to create internal water lines and water jacket features that conform to the
shape of mold geometries without limitations due to conventional machining
methods. Cycle time reductions of 20-35% or more are possible. Additionally,
greater control of cooling design permits improved molded article quality even
with thick wall sections or thick/thin wall combinations.
Complex
geometric control makes MoldFusion particularly effective for structural mass
reduction-the substitution of solid metal mass with structural mold sections.
Truss or honeycomb sections can be built into mold components to improve thermal
isolation and reduce tool weight. Combining structural mass reduction with
selective heating and cooling of the mold during the injection process results
in dynamic thermal cycling. Dynamic thermal cycling enables molding of more
complex designs, longer flow lengths and improved part finish.
MoldFusion
is also a rapid tooling technology for prototype and short-run mold
applications. The combination of continuous improvements in ProMetal build-rate
and near-net shape finish permits the construction of rapid tooling in days with
a favorable cost structure. Near net-shape construction eliminates low-value
rough machine time on high complexity jobs.
D-M-E
Company is one of the world's largest manufacturers and distributors of mold
tooling, mold components, hot runner systems, and electronic controls for the
plastics industry. A subsidiary of Milacron, Inc., D-M-E Company also
manufactures and sells standard tooling for the die casting industry.
Extrude
Hone Corporation is a global machine tool engineering and manufacturing company
providing advanced manufacturing technology solutions including abrasive flow
machining, electrolytic machining, ultrasonic machining, and 3D metal printing.
Services of Extrude Hone include PowerFlow machining services to the racing and
automotive industry and Metrex surface finish metrology software. Primary
markets served by Extrude Hone are aerospace, automotive, diesel, high purity
devices, and dies and molds.
For more information contact:
D-M-E
Company
29111 Stephenson Highway
Madison Heights, MI 48071
248-398-6000
Fax 248-398-6174