Shaping the future of die and moulds: EOS tooling applications

Transcription

1 Shaping the future of die and moulds: EOS tooling applications Augustin Niavas Business Development Manager Tooling Meeting SHL-EOS, Krailling,

2 Index EOS What is DMLS for tooling? How will DMLS be part of the future of the tooling industry? DMLS advantages for injection moulding Hints to advanced tooling design Criteria of choice for inserts for successful testing of technology Applications examples: tool inserts EOS 2010 EOS tooling applications Augustin Niavas Page 2

3 EOS EOS 2010 EOS tooling applications Augustin Niavas Seite 3

4 EOS was founded in worldwide market leader since 2002 for laser-sintering systems EOS History 1989 Founding EOS GmbH - Electro Optical Systems Pilot customer BMW Worldwide market leader for laser-sintering systems, the key technology for e-manufacturing. 60 Mio. Revenue in FY 2008/2009 Approx. 300 people Philosophy Application oriented solutions for numerous industries Technology leader for high-end Rapid Prototyping, Rapid Tooling and Rapid Manufacturing Systems. Joint solutions with customers. Source: EOS EOS 2010 EOS tooling applications Augustin Niavas Page 4

5 In the crisis of 2009 EOS still had a good stand All set for future growth EOS gross revenue and employees [ ] Revenues [Mio. ] Employees Source: EOS EOS 2010 EOS tooling applications Augustin Niavas Seite 5

6 EOS is the worldwide market leader with an installed base in global key regions EOS world-wide 2010 > 900 ystems installed NA: 80 Europe: 630 Asia: 150 ROW: 54 Source: EOS EOS 2010 EOS tooling applications Augustin Niavas Seite 6

7 EOS has subsidiaries or distribution partners in all major markets of the world EOS worldwide 2010 Worldwide recognized technology leader for high-end systems for e- Manufacturing Customers in > 30 countries EOS sales/service/application offices in 10 countries (Germany, UK, France, Italy, USA, India, Singapore, Korea, Taiwan, Finland) Distributors in 22 countries 7 distributors in Asia/Pacific 12 distributors in Europe and ROW Source: EOS EOS 2010 EOS tooling applications Augustin Niavas Page 7

8 Customers from various industries all over the world rely on EOS technologies Sample EOS customers (incomplete) Source: EOS EOS 2010 EOS tooling applications Augustin Niavas Seite 8

9 EOS offers part focused application development Either direct or with partners Collaboration EOS Customer - Partner EOS Parts manufacturer (OEM) R&D Application development System Material Process Partners (e. g. post processing, software, etc. ) Parts Quelle: AKE EOS 2010 EOS tooling applications Augustin Niavas Seite 9

10 EOS verfolgt das Ziel, gemeinschaftlich mit seinen Kunden zur Fertigungslösung zu gelangen Mögliche Grade der Zusammenarbeit mit EOS 1 1 Vertrieb von Standard Systemen, Materialen und Services 2 2 Vertrieb von standardisierten Prozessen (PPP) und Services EOS Situative Kooperation Kunden Vertrieb von standardisierten, branchenspezifischen Anwendungen (z. B. Dental) Kundenspezifische Anwendungsentwicklung Entwicklung von End-to-End Prozessen (vom Design zum Postprocessing) Betreibermodelle Quelle: AKE EOS 2010 EOS tooling applications Augustin Niavas Seite 10

11 Currently EOS has a network of e-manufacturing Partners shaping the future of manufacturing EOS e-manufacturing Partner network Source: EOS EOS 2010 EOS tooling applications Augustin Niavas Seite 11

12 EOS offers the most modern laser-sintering systems for plastics in the market EOS plastics laser-sintering product line EOSINT P 760 EOSINT P 395 FORMIGA P 100 Pictures not scaled Source: CDR EOS 2010 EOS tooling applications Augustin Niavas Seite 12

13 EOSINT P 800 is the first laser-sintering system for high performance polymeres worldwide EOSINT P 800 Source: EOS EOS 2010 EOS tooling applications Augustin Niavas Seite 13

14 The EOSINT M 270 for the direct laser-sintering of metal is a market leading system EOSINT M M 270 operated worldwide Source: CDR EOS 2010 EOS tooling applications Augustin Niavas Seite 14

15 The EOSINT S 750 is used for laser-sintering croning moulding material EOSINT S 750 Source: EOS EOS 2010 EOS tooling applications Augustin Niavas Seite 15

16 EOS offers a wide range of polymer materials suitable for EOS systems PrimePart Polyamide 12 Biocompatible, excellent economics, withstands high mechanical and thermal load PrimePart ST Soft material Flexible, springy, air tight PrimePart DC Polyamide 11 High impact strength, ductile PA 2200 Polyamide 12 Biocompatible, withstands high mechanical and thermal load Quelle: EOS EOS 2010 EOS tooling applications Augustin Niavas Page 16

17 EOS materials are made to meet application requirements PA 2202 black Coloured in black Withstands high mechanical and thermal load PA 2210 FR Flame-retardant polyamide 12 High mechanical properties PA 3200 GF Glass-filled polyamide 12 Hard-wearing, withstands high mechanical and thermal load PrimeCast 101 Polystyrene for lost patterns Minimal remaining ash content Quelle: EOS EOS 2010 EOS tooling applications Augustin Niavas Page 17

18 EOS PEEK HP3 is the first high performance material for laser-sintering in the industry Alumide Aluminium-filled polyamide 12 Dimensionally accurate Machinable, increased thermal conductivity CarbonMide Carbon fibre-filled polyamide 12 Light weight, extreme stiffness and strength, conductive EOS PEEK HP3 Polyaryletherketone Excellent mechanical, chemical and thermal properties Flame-retardant, biocompatible, can be sterilized Quelle: EOS EOS 2010 EOS tooling applications Augustin Niavas Page 18

19 EOS offers a wide range of metal materials suitable for the EOSINT M 270 system DirectMetal 20 Proprietary material specially developed for DMLS Bronze-based mixture Injection moulding tooling, functional prototypes EOS MaragingSteel MS1 Hardenable ultra high strength steel 18 Mar 300 / steel Injection moulding series tooling, engineering parts EOS StainlessSteel GP1 Stainless steel 17-4 / Functional prototypes and series parts, engineering and medical Quelle: EOS EOS 2010 EOS tooling applications Augustin Niavas Page 19

20 With CobaltChrome SP2 EOS has a material tuned to the dental industry s requirements EOS StainlessSteel PH1 Hardenable stainless steel Stainless steel 15-5 / Functional prototypes and series parts, engineering and medical EOS CobaltChrome MP1 High strength, high temperature CoCrMo superalloy Prototypes and series parts, engineering, medical and dental EOS CobaltChrome SP2 Biocompatible CoCrMo superalloy, optimized for ceramic veneering Dental restorations (series production) Quelle: EOS EOS 2010 EOS tooling applications Augustin Niavas Page 20

21 EOS NickelAlloy IN718 is the latest addition to metal materials targeting aerospace applications EOS Titanium Ti64 Biocompatible, corrosion-resistant light alloy Ti6Al4V alloy prototypes and series parts, aerospace, motor sport etc. EOS Titanium TiCP Biocompatible, corrosion-resistant light alloy Pure titanium Functional prototypes and series parts, medical, dental EOS NickelAlloy IN718 High strength, high temperature NiCoCr superalloy Turbines, aerospace and automotive Quelle: EOS EOS 2010 EOS tooling applications Augustin Niavas Page 21

22 What is DMLS for tooling? EOS 2010 EOS tooling applications Augustin Niavas Page 22

23 Definitions: e-manufacturing, DMLS e-manufacturing is the fast, flexible and cost-effective production directly from electronic data. EOSINT M systems builds up, additively layer by layer, metal parts, directly from metal powder, using a focussed laser beam, which fuses metal powder into solid part by melting it locally: this is DMLS. One in particularly most interesting and important field of application is the design for tooling inserts. Source: EOS EOS 2010 EOS tooling applications Augustin Niavas Page 23

24 DMLS with Direct Tool push on tooling design Today Direct Tool means advanced tooling One of the greatest advantages of DMLS is the design driven approach DMLS makes possible the implementation of tools with complex geometry and the realization of heating/cooling channels, designed to follow the moulding surfaces of the tool: this process is known as conformal cooling. Through an optimised positioning of the tempering/cooling system, it s possible to achieve a lower or uniform temperature in the mould and a performing tempering of the tool inserts Schematical comparison between conventional cooling and conformal cooling channels Source: EOS EOS 2010 EOS tooling applications Augustin Niavas Page 24

25 What means conformal cooling? Design driven manufacturing or freedom of design Optimised cooling/heating channels for productivity and quality improvement Reach hot spots and critical areas of the insert High number of possible designs: knowhow dependant suitable to thermodynamics rules and complexity is not a cost-driver Advanced tooling Conventional tooling Possible validation with simulation Uniformity of cooling and improvement of the insert life time Leave under defined circumstances the area of convential tooling and choose a new way for solving challenges Source: EOS EOS 2010 EOS tooling applications Augustin Niavas Page 25

26 EOS offers a wide range of metal materials suitable for the EOSINT M 270 system DirectMetal 20 Proprietary material specially developed for DMLS Bronze-based mixture Injection moulding tooling, functional prototypes EOS MaragingSteel MS1 Hardenable ultra high strength steel 18 Mar 300 / steel Injection moulding series tooling, engineering parts EOS StainlessSteel GP1 Stainless steel 17-4 / Functional prototypes and series parts, engineering and medical Quelle: EOS EOS 2010 EOS tooling applications Augustin Niavas Page 26

27 With CobaltChrome SP2 EOS has a material tuned to the dental industry s requirements EOS StainlessSteel PH1 Hardenable stainless steel Stainless steel 15-5 / Functional prototypes and series parts, engineering and medical EOS CobaltChrome MP1 High strength, high temperature CoCrMo superalloy Prototypes and series parts, engineering, medical and dental EOS CobaltChrome SP2 Biocompatible CoCrMo superalloy, optimized for ceramic veneering Dental restorations (series production) Quelle: EOS EOS 2010 EOS tooling applications Augustin Niavas Page 27

28 EOS NickelAlloy IN718 is the latest addition to metal materials targeting aerospace applications EOS Titanium Ti64 Biocompatible, corrosion-resistant light alloy Ti6Al4V alloy prototypes and series parts, aerospace, motor sport etc. EOS Titanium TiCP Biocompatible, corrosion-resistant light alloy Pure titanium Functional prototypes and series parts, medical, dental EOS NickelAlloy IN718 High strength, high temperature NiCoCr superalloy Turbines, aerospace and automotive Quelle: EOS EOS 2010 EOS tooling applications Augustin Niavas Page 28

29 Definition: EOS MaragingSteel MS1 - high performance steel for series tooling and other applications Characteristics, applications, status Key characteristics 18 Maraging 300 type steel (1.2709, X3NiCoMoTi18-9-5) fully melted to full density for high strength easily machinable as-built age hardenable up to approx. 54 HRC good thermal conductivity and polishability Typical applications series injection moulding (high volume) other tooling applications, e.g. die casting high performance parts, e.g. in aerospace Product status commercial release in 2007 Injection mould insert with conformal cooling, built in EOS MaragingSteel MS1 Source: EOS, Oase EOS 2010 EOS tooling applications Augustin Niavas Page 29

30 Properties: EOS MaragingSteel MS1 is a high performance steel for series tooling and other applications Mechanical and physical properties Mechanical properties as built UTS: 1100 MPa yield strength:1000 MPa hardness: HRC Mechanical properties after age hardening (6 hours at 490 C) UTS: > 1950 MPa yield strength: > 1900 MPa hardness: HRC Physical properties relative density as built: approx. 100 % 200 internally cooled pin inserts for injection moulding, built in EOS MaragingSteel MS1. Source: LBC GmbH Source: EOS, LBC EOS 2010 EOS tooling applications Augustin Niavas Page 30

31 Industry footprint and priority sectors for EOS Aerospace Medical 150 EOSINT M270 worldwide Approx. 25% of the systems are related to tooling applications Biggest amount of systems/company: 10 Tooling Source: EOS EOS 2010 EOS tooling applications Augustin Niavas Page 31

32 EOSINT M 270 reference users in tooling business Manufacturer (OEM s): Hella Automotive lighting and Electronic supplier Continental/ Siemens VDO Production & R&D Gillette / Procter&Gamble Direct part, tooling & R&D Sharp Direct part in production & tooling Source: EOS EOS 2010 EOS tooling applications Augustin Niavas Page 32

33 How will DMLS be part of the future of the tooling industry? EOS 2010 EOS tooling applications Augustin Niavas Seite 33

34 DMLS suits trends in tooling and injection moulding Complexity of the tooling inserts and of the plastic product Complexity is not a cost driver Carbon foot print in line or inferior as existing technology Energy saving technology Faster lead times DMLS is an energy saving technology for tooling and injection moulding Source: EOS, Oase EOS 2010 EOS tooling applications Augustin Niavas Page 34

35 DMLS: Parts already in production, technology potential still growing and developing Introduction Growth Maturity Decline High speed milling EDM Sales Electrical IMM DMLS Time EOS 2010 EOS tooling applications Augustin Niavas Seite 35

36 The business development growths along 3 axis M2XX as serial production machine DMLS as reference technology: the use of the technology and the possibilities it offers has to be diffused (reach the decision makers, industrial associations, etc ) Cooperations to speed up improvement: all over the manufacturing chain, from advanced tooling trainings suppliers to toolmakers, from software companies to research institute EOSINT M systems as serial production machine for tooling: gather the customers and market feedback, works together with product management to explore completely the potential of the machine DMLS as reference technology The three development axis Cooperations as improvement catalysers Source: EOS EOS 2010 EOS tooling applications Augustin Niavas Page 36

37 DMLS advantages for injection moulding EOS 2010 EOS tooling applications Augustin Niavas Seite 37

38 DMLS has a positive impact on the injection moulding manufacturing chain The example concerns a thin-walled throw-away product (cheap raw material) DMLS has a selective effect on the costs along the manufacturing chain Advantages for inserts costs, productivity, cycle time, product quality and material usage Effects are additionally positive Production cost distribution for product PS coffee cup Source: Spritzgießtechnik Verarbeitung Maschine Periferie Hanser Verlag, 2004 EOS 2010 EOS tooling applications Augustin Niavas Page 38

39 Advantages for tooling inserts Complexity is no cost-driver Lower price/insert thanks optimised use of the construction platform Reduction of Lead times (Cooling system and inserts are built at the same time) Hybrid approach save costs High refresh rate for MS1 PEP Project for ABS products ( parts, Legrand electrical components): lower costs and reduced lead time Source: PEP EOS 2010 EOS tooling applications Augustin Niavas Page 39

40 Influence on the injection molding process Advantages in terms of productivity Tempering system effectivity allows up to 60% cycle time reduction Mould opening - ejection Mould closing Injection carriage in Filling Cooling time Better control of the process Optimised workload and machine costs saving Better quality of the product Cycle time diagram Source: LBC, EOS, Spritzgießtechnik Verarbeitung Maschine Periferie Hanser Verlag, 2004 EOS 2010 EOS tooling applications Augustin Niavas Page 40

41 Breakeven analysis illustrates economical benefits of DMLS in comparison to conventional tooling Costs & revenue Possible initial additional costs with DMLS inserts Advantages in terms of cost saving Profit Total revenue Total costs conventional tooling Total costs DMLS Fixed costs DMLS Fixed costs conventional tooling Lower cycle time Q DMLS Q Conventional tooling Quantity of products Source: Inglass, EOS EOS 2010 EOS tooling applications Augustin Niavas Seite 41

42 Heating/cooling has the most important influence on product quality Advantages in terms of product quality 60% of defects on products come from wrong or not efficient mould temperature control Mould temperature control Hot runner choice Process stability Maintenance 25% hot runner choice 10% 5% 10% process stability 5% maintenance 25% 60% Different factors influencing quality of product parts in injection moulding Source: EOS, GTT GmbH EOS 2010 EOS tooling applications Augustin Niavas Page 42

43 Positive effects on products and material consumption Advantages in terms of product quality Conformal cooling Conventional cooling Cavity side (cold) Lower scrap rate: advantages in terms of reducing costs can be quantify: Euro for inserts parts, 2 Euro/product 25% scrap rate Core side (hot) Reduction of warpage and shrink mark thanks cooling uniformity of product Higher product quality and stability with the same amount of material Core side (hot) DMLS friendly rules will allow the manufacturing of lighter products with the same mechanical properties 175 Example of quality issues on PP-T20 product. Conformal cooling allows drastic reduction of scrap rate Source: EOS EOS 2010 EOS tooling applications Augustin Niavas Page 43

44 Positive effects for products and material consuming Advantages in terms in material consuming Lower scrap rate Reduction of warpage and shrink mark thanks cooling uniformity of product Higher product quality and stability with the same amount of material DMLS friendly rules allow the manufacturing of lighter products with the same quality Source: EOS, LBC EOS 2010 EOS tooling applications Augustin Niavas Page 44

45 Hints to advanced tooling design EOS 2010 EOS tooling applications Augustin Niavas Seite 45

46 Design recommendations (1) Do not hesitate to boost your cooling system if necessary Cool down critical area, reaching them with free form shape Give preferences to smooth lines, avoid right corners Follow the contour of your insert and keep distance to surface/wall constant If you need to split your channels, then take care of balancing them. Source: LBC EOS 2010 EOS tooling applications Augustin Niavas Seite 46

47 Design recommendations (2) Boundary box 250x250x190 Reduce if possible to amount of material to be processed Think DMLS in designing your insert DMLS light for cross section Green Orange Red Boundary box and cooling channel sections 250 Source: LBC. EOS EOS 2010 EOS tooling applications Augustin Niavas Page 47

48 Design recommendations (3) Characteristics, applications Design rules (EOS Whitepapers and other documentation) Recommendations about distances, diameters Knowledge optimized mould temperature control Same rules for DMLS cooling/heating or conventional mould temperature control Wallthickness of injection moulding part (in mm) Hole diameter (in mm) Centerline spacing between holes Distance between center of holes and cavity b a c x b x b Source: EOS EOS 2010 EOS tooling applications Augustin Niavas Page 48

49 Example cooling lines (1) Density of cooling lines have been increased Conformal path has been increased Source: BBE, EOS EOS 2010 EOS tooling applications Augustin Niavas Page 49

50 Example cooling lines (2) Cool down critical area, reaching them with free form shape Give preferences to smooth lines, avoid right corners Follow the contour of your insert and keep distance to surface/wall constant Source: BBE, EOS EOS 2010 EOS tooling applications Augustin Niavas Seite 50

51 Criteria of choice for inserts for successful testing of technology EOS 2010 EOS tooling applications Augustin Niavas Seite 51

52 The roadmap to the successful process Identify the most suitable geometry (core or cavity) Dimensional criteria Complexity criteria Challenging injection process Free form shape DMLS oriented design from the beginning (if possible) Cooperate with us and our service provider to optimise or the create the design (best case) Follow the basic design rules Send us the 3D Data (under NDA if necessary) EOS builds the inserts, you test it EOS 2010 EOS tooling applications Augustin Niavas Page 52

53 3 types of criteria should guide us to a suitable case study Principal criteria Geometrical: parts/insert should fit into the building envelope (with or without hybrid) Material requirements: Maraging steel material of choice Case study free of NDA Application criteria Industry sector: packaging, medical, electrical and domestical appliances Complexity of heating/cooling system Innovation Potential Plastic product criteria Cycle time reduction potential High scrape rate Source: EOS EOS 2010 EOS tooling applications Augustin Niavas Page 53

54 Conventional Tooling characteristics vs. Advanced Tooling characteristics Back-up Qualitative comparison between the two different type of processes Conventional Tooling type Advanced Tooling Poor Canal cross section Excellent Tempering system complexity Material costs Part size Durability Design flexibility (part complexity) Product quality Source: EOS EOS 2010 EOS tooling applications Augustin Niavas Seite 54

55 Applications examples: tool inserts EOS 2010 EOS tooling applications Augustin Niavas Page 55

56 Part description of the Polymold case study Product description Children s goblet made of high quality plastic (Polypropilene), made on one cavity mould Data of conventional and DMLS process available (tooling and IM machine/process) Objective of the project Complete comparison between DMLS and conventional manufacturing chain Improvement of product quality Cycle time reduction Example of hybrid tool Source: BKL, Polymold, EOS EOS 2010 EOS tooling applications Augustin Niavas Page 56

57 DMLS reduces cycle time up to 42% in project child gobelet (Polymold) Solution Hybrid tool, one cavity DMLS tool insert with conformal cooling channels Hardness: HRC Surface finish: high gloss polish Building time: 35 hours Advantages Reduction of scrap rate Reduction of product warpage * Cycle time reduction: from 24 seconds to 13,8 seconds, which mean a reduction of 42,5% * Cost saving (on a yearly base, Products/year): circa Euro * Tool insert Polymold child gobelet: core Source: EOS, Polymold, BKL, EOS EOS 2010 EOS tooling applications Augustin Niavas Page 57

58 Comparison of conventional design insert with DMLS design insert Conventional cooling system (left), DMLS cooling channels (right) Source: BKL, Polymold, EOS EOS 2010 EOS tooling applications Augustin Niavas Page 58

59 Simulation confirms design choice and allows to predict process results Simulation of the insert with cooling lines in core Source: BKL, Simcon EOS 2010 EOS tooling applications Augustin Niavas Page 59

60 Particularity of the cooling system Conformal cooling: - not manufacturable conventionally - the integrated cooling system increases tool insert life time Advantage : - cycle time reduction up to 40% - Better and uniform temperature balance Design advantages : - equilibrated linear coolant flow - improved flow speed in the cooling channels Cross section of the cooling channels with long hole shape: - improves the cooling performance of the tool insert - not manufacturable conventionally EOS 2010 EOS tooling applications Augustin Niavas Page 60

61 Particularity of the DMLS tool insert Tool insert for the manufacturing of child cup, material EOS Maraging Steel MS1 (1.2709) Hardness tool insert: HRC DMLS manufacturing High glossy polish finishing Hybrid design Conventional manufacturing Conventional cooling system (left), DMLS cooling channels (right) Source: BKL, Polymold, EOS EOS 2010 EOS tooling applications Augustin Niavas Page 61

62 Particularities of the plastic product Ideal temperature distribution reduces warpage in plastic product Productivity increase up to 70% Reduction of scrap rate EOS 2010 EOS tooling applications Augustin Niavas Page 62

63 Tooling video shows benefits for injection moulding EOS 2010 EOS tooling applications Augustin Niavas Page 63

64 Building strategy has a positive impact on tooling costs Challenge Reduce the cycle time Save costs with the right building strategy Solution Horizonzal building strategy Insert built in EOS MaragingSteel MS1. Benefits Building strategy saves 50% of building time Cycle time reduction: 28% Example of hybrid tool Source: LBC EOS 2010 EOS tooling applications Augustin Niavas Page 64

65 DMLS advantages have a positive impact all over the manufacturing chain Challenge Manufacture a tooling insert for large-volume production Optimise the design of the tooling insert Solution Upper insert built on an existing moulding blank Reduction of the volume of sintered material Benefits Hybrid approach saves costs of tooling insert Cycle time reduction: 35% Reduction of scrape rate products manufactured Example of hybrid tool Source: LBC EOS 2010 EOS tooling applications Augustin Niavas Page 65

66 Serial production tooling in production (more than 2 years) Challenge Reach hot spots area Reduce cycle time Solution 12,5 m length cooling channels 5x parallel cooling channels and 4x parallel cooling channels Benefits 50% cooling time reduction Examples of cooling lines and hybrid insert Source: LBC EOS 2010 EOS tooling applications Augustin Niavas Page 66

67 Hybrid approach saves tooling costs Challenge Manufacture a high complex heat/cooling system (not possible conventionally) Optimise the design of the tooling insert Solution Thermal analysis to confirm the better performance of the conformal cooling system Insert built in EOS MaragingSteel MS1 Size: 226x 204 mm (lxh) Benefits Hybrid approach saves costs of tooling insert Free form shape surface cooling possible Examples of cooling lines and hybrid insert Source: Inglass S.r.l EOS 2010 EOS tooling applications Augustin Niavas Page 67

68 Hybrid approach saves tooling costs Challenge reduce cycle time remove aesthetical problems due to bad cooling of the upper part of the insert Benefits elimination of defects on the aesthetical side of the part cycle time reduced from 66 down to 60 seconds. Waste due to scraps on production of parts % scraps Molding process cost / piece[ ] Material cost / piece[ ] Waste for scraps [ ] SLM 0.5% 3,000 7, Tradit. 2.0% 3,300 7, Cost of molding process for the production of parts SLM t CYCLE [s] 60 Pieces / cycle 1 Machine and direct labor cost per hour [ /h] 180,00 Press machine [tonn] 2200 Machine and direct labor cost[ /pz] 3,000 DMLS ,00 Examples of cooling lines on hybrid insert Tradit , ,300 Source: Inglass S.r.l EOS 2010 EOS tooling applications Augustin Niavas Page 68

69 Case study for HR nozzle with DMLS cooling bushing Description: SLM bushing with conformal channels for injection gate conditioning. This device is used for molding of a PC transparent chair, 2.700gr heavy, injected by single nozzle. Objective: eliminate burning defects on the injection point due to shear heating effect on the gate. Cost saving DMLS ,00 Results: no burning defects on the injection gate, comparing to a similar part, cycle time was reduced from 128 down to 110 s. Cost of molding process for the production of parts t CYCLE [s] Pieces / cycle Machine and direct labor cost per hour [ /h] Press machine [tonn] Machine and direct labor cost[ /pz] SLM , ,483 Tradit , ,053 Money waste due to scraps on production of parts % scraps Molding process cost / piece[ ] Material cost / piece[ ] Waste for scraps [ ] SLM 0.5% 3,483 7, Tradit. 3.5% 4,053 7, Source: Inglass EOS 2010 EOS tooling applications Augustin Niavas Page 69

70 Tool insert for a fashion industry product Challenge Improve the cooling performance of the conventional insert Solution Optimisation thanks to conformal cooling system Insert built in EOS MaragingSteel MS1 20 µm layer thickness, polished Benefits 42% cycle time reduction Improved product quality Tool inserts for lipstick lids Source: BKL-Lasertechnik EOS 2010 EOS tooling applications Augustin Niavas Page 70

71 Cycle time reduction allows cost saving and better product quality Solution Simulation of the process to optimise the cooling system Insert built in EOS MaragingSteel MS1 Benefits 55% cycle time reduction (von 90 to 40 seconds) parts per year Inserts costs: Euro Cost saving: Euro Amortisation time: 2 months High Injection moulding machine hours saving (555 hours that is from 1000 hours to 444 hours) Better product quality Tool insert for injection moulding Source: LBC EOS 2010 EOS tooling applications Augustin Niavas Page 71

72 DMLS can be applied to die casting too Challenge Build an insert for a die casting application Tool insert life time likely inserts conventionally manufactured Solution Cooling system optimisation Insert built in EOS MaragingSteel MS1 Benefits 20% cycle time reduction parts manufactured in serial production Tool insert for die casting Source: LBC EOS 2010 EOS tooling applications Augustin Niavas Page 72

73 Insert reparation with DMLS is costs and time saving Challenge Replace a partially damaged insert without building it completly Solution Generation of a new reference surface (sharpening/grinding) Positioning of the part in the machine On top construction of the missing parts Benefits Save costs of a complete new insert construction High reduction of lead time (partial construction instead of complete construction) Tool insert reparation: before (under) and after the use of DMLS (upper). Source: Ecoparts EOS 2010 EOS tooling applications Augustin Niavas Page 73

74 Integration of DMLS inserts into machined tool base allows very rapid production tooling Challenge Series production tool for injection moulded plugs in PBT GF10% Tool availability as quickly as possible Solution 3-cavity mould in hybrid concept Machined aluminium tool base with inserts in EOS MaragingSteel MS1 (1.2709) Benefits Tool availability: 6 working days No need of pre-series tooling due to rapid delivery of production mould Reduction of tooling costs Production mould with inserts in EOS MaragingSteel MS1, built on EOSINT M 270 Source: FIT EOS 2010 EOS tooling applications Augustin Niavas Page 74

75 DirectTool with EOSINT M and DirectMetal 20 ideal for rapid and economical low-volume production Challenge injection molding tooling for a guide adaptor production quantity 5,000 parts annually in Polycarbonate Solution DirectTool on EOSINT M 270 with DirectMetal 20 material modular tool concept: aluminum block with DMLS insert built in DirectMetal 20 on EOSINT M 270 Benefits Tool availability: 5 days Tooling cost reduction Modular tool for a guide adaptor Source: General Pattern Inc EOS 2010 EOS tooling applications Augustin Niavas Page 75

76 EOS GmbH Electro Optical Systems Robert-Stirling-Ring 1 D Krailling Germany Tel: Fax: info@eos.info web: EOS, EOSINT, DMLS, DirectPart, DirectTool, DirectPattern, DirectCast and Alumide are registered trademarks of EOS. Source: EOS EOS 2010 EOS tooling applications Augustin Niavas Seite 76

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