DMLS OF INJECTION MOULD INSERTS FROM 2004 UNTIL TODAY LBC LaserBearbeitungsCenter GmbH Im Moldengraben 34 D-70806 Kornwestheim Tel.: 07154/80 88-0 Fax: 07154/80 88-28 E-Mail: Info@LBC-GmbH.de Internet: www.lasergenerieren.de.
DMLS current status Basics about LBC engineering solutions Implementation, Here we are today Needs for the future Technology (EOS) Market
DMLS current status Basics about LBC engineering solutions Implementation, Here we are today Needs for the future Technology (EOS) Market Possible mould solutions
LBC offers the generative manufacturing of metal parts since 2004 as a service. Therefore LBC is one of the pioneers using this technology, especially in mould and diecasting applications. At the beginning we used the Trumaform LF 250 from TRUMPF. Since 2006 LBC is using the M270 from EOS.
LBC was able to boost the acceptance and request for lasergenerated moulds, prototypes and serial parts constantly. In March 2008 the manufacturing capacity was increased to 2 machines. In December 2009 the third machine was installed. Air conditioned manufacturing cell
Today LBC is especially for the mould and diecasting market the service supplier with the biggest manufacturing capacity for lasergenerated parts in Germany. Facts: approx. 95% of the lasergenerated parts are. conformal cooled inserts. approx. 4% of the lasergenerated parts are. for serial applications approx. 1% of the lasergenerated parts are. prototyps. 2010 LBC was consuming approx. 1600 kg. of the material 1.2709, tendency is increasing. One bottle corresponds with 10 kg powder material
DMLS current status Basics about LBC engineering solutions Implementation, Here we are today Needs for the future Technology (EOS) Market
engineering: LBC is now commercially introducing a professionally engineered approach. The focus of this approach is analyzing new or existing moulds, reviewing the thermal efficiency, then optimize the design, resulting in the manufacture of Tailored conformal cavity cooling. As experts in the lasergenerating manufacturing processes as well as our strength in developing and designing injection moulding tools LBC can offer you the opportunity to see what can do for your projects. For the best part quality and most efficient production, should be your first choice. is the LBC brand for individual, customer specific solutions with conformal cooling and the manufacturing of lasergenerated mould inserts.
engineering - helpdesk: The technology Lasergenerating is offered by LBC as services. Since 2004 we were able to establish a hugh know-how. This knowledge is the base to realize customer wise tasks. Especially for new customers our detailed helpdesk is the needed support to erase the respect or fear regarding this new technology In an open discussion about all facts, the customer receives all background information he needs. This is the base for a good, future cooperation and the key for our success.
engineering - design: In order to support our customers when optimizing the realisation of conformal cooled inserts and moulds, LBC offers the design of the channel inside the customer's mould. LBC provides the customer with the design data in 3 D for their approval.
engineering - design: Information: This conformal cooling system is used in an insert since more than 4 years. Geometry: Ellipse standing 1,3 mm x 1,8 mm equates Ø 1,53 mm 2 closed loops 1x 4-times parallel 1x 5-times parallel Is running with 6 bars and filtering Cooling medium: water Total length of all channels is 12.500 mm! Cooling cycle is the half!
engineering - design: Flow demonstration: Geometry: Ellipse standing 1,3 mm x 1,8 mm equates Ø 1,53 mm 1 closed loop 1x 4-times parallel Each channel is 800 mm long. Is running with 3 bars Cooling medium: water Total length of all channels is 3.200 mm!
Information: engineering - design: Complex mould require an extensive design to realize a perfect cooling. This design is based on fundamental know-how of the designer. So it was possible to provide this channel system. 8 channels with Ø 3 mm and nearly identical length branch out of a 10 mm input. This guaranties identical flow in all channels.
Information: engineering - design: Sample of an extensive design to realize a perfect cooling.
engineering - simulation: The simulation of the expectable cycle time reduction is no manageable with any simulation software, because of the complexity of the conformal cooling systems caused by Lasergenerating. As simulation is the key to check on the efficiency of cooled inserts, LBC offers this simulation as a service. So the customer's purchasing department receives facts for their decision.
engineering - simulation: basics Information: The simulation of a conformal cooling is done together with a flow analysis. Using the software LBC has a tool, to implement the total design of conformal cooling channels. Therefore we need the following article as 3D CAD data, injection points, form of the injection (e.g. hot runner), plastics with data sheet, process parameters injection CAD data of the conventional cooling, cooling data, flow volume, pressure, number of closed loops, temperatures etc.
engineering - simulation: Temperature difference Information:
engineering - simulation: Reynolds number
DMLS current status Basics about LBC engineering solutions Implementation, Here we are today Needs for the future Technology (EOS) Market Possible mould solutions
realized mould inserts Information: Laser generated cooling core insert for a 2- components injection mould for an ice scraper. By the integrated cooling ducts close to contour, the cycle time could be reduced from 80 seconds to 40 seconds. Thus allows the production of twice as much parts.
realized mould inserts Information: conformal cooled insert with closed loop cooling channels
LASERGENERATING realized mould inserts Thermografy:
Lasergenerating on a premanufactured hybrid blank Signification of the hybrid technology Information: Reduction of the generatable volume to the needed minimum for an effective cooling. Dramatically reduce of the manufacturing costs. Gain of the lasergenerating profitability. More effective use of the laser capacity.
Lasergenerating on a premanufactured hybrid blank Fitting basic material: Information: 1.2709 (Böhler W722 VMR) deliverable up to Ø122 mm turned and as 150 x 150 mm square Vacumar from Zapp, martensite steel analogue 1.2709. All dimensions are deliverable. The use of 1.2343 or 1.2083 is not possible!! You will have a big danger for cracks. Crack of a hybrid blank 1.2083 (hardened)
realized mould inserts, using a hybrid blank Information: Insert lasergenerated on a hybrid blank Using this premanufactured volume the production cost could be dropped 50%. The hybrid material has to be also 1.2709 mould making steel.
realized mould inserts, using a hybrid blank Information: Conformal cooled mould insert, on a premanufactured hybrid blank. Without using the hybrid solution, this insert would not have been manageable economically and the run time of the machine would have been to long.
DMLS current status Basics about LBC engineering solutions Implementation Here we are today Needs for the future Technology (EOS) Market Possible mould solutions
Here we are today In 2004 the acceptance of the lasergenerating was more or less ZERO. Nearly no mould maker wanted to believe in this new technology. A lot of question had to be answered and it was a hugh challenge to get the first orders. Nearly no mould maker wanted to be first! They did not accept the surface roughness and could not believe that the material property will fit to their needs. Detecting the outside zero point with a touch probe was not as easy as with today's surfaces, built on a M270.
Here we are today Surface roughness of an insert produced on the Trumaform LF250 at LBC. Material: 1.2343 Layer thickness: 0,1 mm
Here we are today Surface roughness of an insert produced on the M270 at LBC. Material: 1.2709 Layer thickness: 0,04 mm
Here we are today Limits: The volume rate is still limited The maximum size of generatable inserts is limited Will the channels get blocked? Is the material property good enough? What is the lifetime of such an insert? Will the higher costs be paid by the injection moulder, who has the benefit? Still no content of teaching at Universities Still no content of teaching at professional schools
Here we are today Technology EOS: The new M280 is an important step into the right direction. The volume rate will be growing nearly 100%. Parts up to 300 mm, especially hybrid solutions, can be lasergenerated in. one piece.
DMLS current status Basics about LBC engineering solutions Implementation, Here we are today Needs for the future Technology (EOS) Market
Technology EOS: LBC s wishes for the next generation of M-series are: The volume rate should be improved as much as possible More different sizes of the building chamber This machine has to be designed for mass production issues Costs down, especially for spare parts and service
DMLS current status Basics about LBC engineering solutions Implementation, Here we are today Needs for the future Technology (EOS) Market Possible mould solutions
Market: Having machines with highest productivity the market would be enormous. Starting with the M280 we will able to compete against several other solutions of conformal cooling as: soldered inserts diffusion welding hugher and longer inserts will be manageable New application will follow step by step!