Omni Mold was approached by their customer to address the issue of inefficient cooling in one of the mould core insert. The existing mould uses a conventional cooling design with a spiral-shaped core insert. The cooling was uneven and there were hotspots that led to deformation of moulded parts. Various solutions were considered to address the hotspot issue, including prolonged moulding cycle time to resolve dimensional and warpage issues.
By investing in a SLM®️280 2.0 , Omni Mold was able to completely reimagine the cooling channel within its mould inserts through laser-fast additive manufacturing. AM enables the manufacture of complex parts, in this case, replacing the spiral shape with a conformal cooling channel that targets the hotspot areas and improves cooling efficiency within the injection mould. This allows for uniform cooling across the entire product, thereby improving overall part quality, minimizing distortion, and shortening the cycle time during production.
Through much internal testing and development, Omni Mold is now capable of producing hybrid inserts to cater to their customer’s requirements – all with shorter lead time and lower costs. The numbers speak for themselves: The total print time was reduced by 88.75% from 120 hours to 19.5 hours for a full print using a hybrid printing method. The moulding cycle time was also reduced by 44%, from 45 seconds to 25 seconds.
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