Metal 3D printing technology is widely applied in the design and manufacturing of molds, cores, and conformal cooling channels in injection molding processes. In this article, we will introduce how leveraging 3D printing optimizes conformal cooling channel designs.
What are Conformal Cooling Channels?
Conformal cooling channels are passages designed to mirror the contours of the mold core or cavity, facilitating swift and even cooling during injection molding or blow molding processes. These channels typically have curved, irregular, or highly variable shapes, resembling natural water bodies. By closely following the contours of the product, they enhance cooling efficiency and uniformity, thereby reducing manufacturing cycles and improving product quality. The design of conformal cooling channels can be manufactured using 3D printing technology, allowing for more intricate and flexible channel designs that enable more effective cooling in areas inaccessible compared to traditional channels.
What kind of Molds are Suitable for 3D-printed metal Conformal Cooling Channels?
The Conformal Cooling Channels are ideal for businesses seeking high production efficiency and yield. The advanced channel design not only allows for precise control of the cooling process but also enables highly customized configurations according to product requirements. In particular, molds with complex geometries requiring precise cooling or special material requirements are ideal candidates for leveraging the technique. Traditional mold manufacturing is limited by tooling and thus can not achieve intricate channel design. However, metal printing overcomes this limitation, having the ability to design channels of nearly any shape. The effectiveness of 3D printed channels is particularly evident when dealing with shapes that require nonlinear or complex 3D woven designs.
Waterway Shape Reference
Design Guidelines:
- Layout – Channels should be evenly distributed along the shape of the injection molding part.
- Shape and Length – Circular shapes are preferred, but elliptical or triangular are accepted; lengths should be moderate.
- For channels with a width of 3mm(=0.118inch), lengths should be below 500mm(=19.7inch).
- For channels with a width of 6mm(=0.236inch), lengths should be below 1000mm(=39.4inch).
- Transitions – The cross-sections of the channels should have smooth transitions, avoiding any 90-degree sharp corners.
- Width- Channels do not necessarily need to be of equal width. Some moderate transitions in channel diameters according to spatial requirements are acceptable.
- Distance from Mold Surface to the Channels(general recommendation) – The distance can be adjusted based on the specific application and design but channels should be at least 3-5mm(0.118-0.20inch) away from the mold surface.
- Distance from Mold Surface to the Channels(Special Circumstances) – The distance can be adjusted based on specific applications and material but an ideal distance ranges from 0.5mm to 1mm(0.020-0.039inch).
- Cooling Efficiency: Cooling efficiency exhibits an exponential relationship with the distance from channels to the mold surface. In other words, cooling effectiveness decreases when the distance is increased. Therefore, channels should be as close to the mold surface as possible, while ensuring no threat to the structural integrity of the mold.
- Mold Flow Analysis: Mold flow analysis software are great methods to validate channel designs, help to determine the optimal channel locations, and flow rates, and further predict cooling effectiveness.
Want to improve the deformation created by plastic injection molding? You might want to switch to metal printing.
Injection molding often results in deformation in plastic molds. primarily due to uneven mold temperatures. Metal 3D-printed conformal cooling channels closely adhere to the mold’s demolding surface, ensuring uniform cooling. This minimizes thermal stresses, improves the assembly accuracy, and further enhances the appearance, especially for parts with opening or flat components that tend to deform relatively easily.
How to Enhance Cooling Efficiency When Mold Cooling Channel Space is Limited?
For instance, we’ve dealt with a mold for an electric toothbrush handle. The handle has really narrow internal spaces, with the narrowest point being only 5.14mm(=0.202inch). By utilizing 3D printing, we widened the channel diameters and increased the flow rates to achieve even cooling. As a result, the cooling time for the product was reduced from 19.5 seconds to 13.2 seconds, yielding a 33% efficiency improvement.
Full Metal Printing or Metal 3D Printed Inserts
For metal molds, both full and hybrid metal printing have their application and advantages. Full metal printing is suitable for projects with small components, tight deadlines, and the need for comprehensive efficient cooling. It ensures a smooth flow of channels, thereby enhancing cooling effects and shortening production cycles. Conversely, printed inserts involve localized 3D printing on a pre-machined base, potentially saving cost and time in material usage and manufacturing. This approach is particularly beneficial for molds that only require cooling optimization only for specific portions.
In conclusion, InstaVoxel provides a comprehensive solution, encompassing mold flow analysis, as well as the design and manufacturing of metal 3D-printed Conformal cooling channels. Our technical team possesses extensive experience and expertise, delivering customized solutions tailored to your precise requirements. Contact us for all your manufacturing needs and bring your project to life with precision and efficiency!
