Fokus: PLAST Lund 4-5 maj Lunds Tekniske Högskola

Transcription

1 Fokus: PLAST Lund 4-5 maj Lunds Tekniske Högskola Production of injection moulds using AM technology - LaserCUSING Martin Nielsen, Product Manager Concept-Laser

2 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)

3 Who is Signcom 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

4 Our Customers

5 Our Customers

6 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, Complete melting of the powder materials, therefore almost 100% density of the components Build rate: cm3 / h (depending on the density and geometry)

7 What is LaserCUSING Hotwork steel CL 50WS (<= 54 HRC) Closed surfaces, like microwelding Builds layer buy layer ( mm) Density close to 100% (100 x enlarged) Surface LaserCUSING CL 50WS Internal structure LaserCUSING CL 50WS

8 What is LaserCUSING

9 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

10 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)

11 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 )

12 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%)

13 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

14 Examples of use Insert for steam iron Source: ROWENTA Mould: 4-cavity ( 3K ) Insert: 4 x CL 50WS Reduction of cycle time: 30%

15 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)

16 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

17 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.

18 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

19 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)

20 Flip-Cap (project NeuroTemp) Injection side Ejection side

21 Flip Cap conventionaly cooling design

22 Flip Cap design of LaserCUSING inserts

23 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

24 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

25 Measurement report (example) Y X

26 Location of the measuring points

27 Y - deviation 4 cooling time[s] LaserCUSING gebohrt 15-1,6-1,4-1,2-1 -0,8-0,6-0,4 Y deviation [mm]

28 X - deviation 4 cooling time [s] LaserCUSING gebohrt 15-0,15-0,1-0,05 0 0,05 0,1 0,15 0,2 X deviation [mm]

29 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)

30 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

31 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

32 Simulation of paralell LaserCUSING cooling

33 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

34 Agenda The impossible has become possible. Thank you for your attention