eos tooling applications - asiannet · 2014-04-02 · eos 2010 eos tooling applications...
TRANSCRIPT
Shaping the future of die and moulds: EOS tooling applications
Augustin NiavasBusiness Development Manager Tooling
Meeting SHL-EOS, Krailling, 27.05.2010
EOS 2010� EOS tooling applications� Augustin Niavas Page 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 Seite 3
EOS
EOS 2010� EOS tooling applications� Augustin Niavas Page 4
EOS was founded in 1989 - worldwide market leader since 2002 for laser-sintering systems
EOS History
Source: EOS
Founding EOS GmbH - Electro Optical SystemsPilot customer BMW.
Philosophy
1989
2002
Worldwide market leader for laser-sintering systems, the key technology for e-Manufacturing™.
Application oriented solutions for numerous industriesTechnology leader for high-end Rapid Prototyping, Rapid Tooling and Rapid Manufacturing Systems.Joint solutions with customers.
200960 Mio. € Revenue in FY 2008/2009Approx. 300 people
EOS 2010 � EOS tooling applications� Augustin Niavas Seite 5
In the crisis of 2009 EOS still had a good stand – All set for future growth
EOS gross revenue and employees [2003 - 2009]
Source: EOS
Revenues[Mio. €]
Employees
48
2005
187
38
2003
157
44
2004
172
52
2006
207
2007
60
250
2008
280
70
60
2009
300
EOS 2010 � EOS tooling applications� Augustin Niavas Seite 6
EOS is the worldwide market leader with an installed base in global key regions
EOS world-wide 2010 – > 900 ystems installed
Source: EOS
Europe: 630
Asia: 150
NA: 80
ROW: 54
EOS 2010� EOS tooling applications� Augustin Niavas Page 7
EOS has subsidiaries or distribution partners in all major markets of the world
EOS worldwide 2010
Source: EOS
— 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
EOS 2010 � EOS tooling applications� Augustin Niavas Seite 8
Sample EOS customers (incomplete)
Source: EOS
Customers from various industries all over the world rely on EOS technologies
EOS 2010 � EOS tooling applications� Augustin Niavas Seite 9
Collaboration EOS – Customer - Partner
Quelle: AKE
EOS offers part focused application development –Either direct or with partners
EOS Parts manufacturer (OEM)
System
Material
Process
PartsPartners (e. g. post processing,
software, etc. …)
R&D
Application development
EOS 2010 � EOS tooling applications� Augustin Niavas Seite 10
Mögliche Grade der Zusammenarbeit mit EOS
Quelle: AKE
EOS verfolgt das Ziel, gemeinschaftlich mit seinen Kunden zur Fertigungslösung zu gelangen
EOS Kunden
1
2
3
4
5
6
Vertrieb von Standard Systemen, Materialen und Services
1
Vertrieb von standardisierten Prozessen (PPP) und Services
2
Vertrieb von standardisierten, branchenspezifischen Anwendungen (z. B. Dental)
3
Entwicklung von End-to-End Prozessen (vom Design zum Post-processing)
5
Betreibermodelle6
Kundenspezifische Anwendungsentwicklung
4
Sit
uati
ve K
ooperati
on
EOS 2010 � EOS tooling applications� Augustin Niavas Seite 11
EOS e-Manufacturing Partner network
Source: EOS
Currently EOS has a network of e-Manufacturing Partners shaping the future of manufacturing
EOS 2010 � EOS tooling applications� Augustin Niavas Seite 12
EOS offers the most modern laser-sintering systemsfor plastics in the market
EOS plastics laser-sintering product line
Source: CDR
Pictures not scaled
FORMIGA P 100EOSINT P 395EOSINT P 760
EOS 2010 � EOS tooling applications� Augustin Niavas Seite 13
EOSINT P 800 is the first laser-sintering systemfor high performance polymeres worldwide
EOSINT P 800
Source: EOS
EOS 2010 � EOS tooling applications� Augustin Niavas Seite 14
The EOSINT M 270 for the direct laser-sintering of metal is a market leading system
EOSINT M 270
Source: CDR
150 M 270
operated
worldwide
EOS 2010 � EOS tooling applications� Augustin Niavas Seite 15
The EOSINT S 750 is used for laser-sintering croningmoulding material
EOSINT S 750
Source: EOS
EOS 2010� EOS tooling applications� Augustin Niavas Page 16
Quelle: EOS
— 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
EOS offers a wide range of polymer materials suitable for EOS systems
EOS 2010� EOS tooling applications� Augustin Niavas Page 17
Quelle: EOS
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
EOS 2010� EOS tooling applications� Augustin Niavas Page 18
Quelle: EOS
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
EOS 2010� EOS tooling applications� Augustin Niavas Page 19
Quelle: EOS
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 / 1.2709 steel
• Injection moulding series tooling, engineering parts
— EOS StainlessSteel GP1
• Stainless steel 17-4 / 1.4542
• Functional prototypes and series parts, engineering and medical
EOS 2010� EOS tooling applications� Augustin Niavas Page 20
Quelle: EOS
With CobaltChrome SP2 EOS has a material tuned to the dental industry’s requirements
— EOS StainlessSteel PH1
• Hardenable stainless steel
• Stainless steel 15-5 / 1.4540
• 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)
EOS 2010� EOS tooling applications� Augustin Niavas Page 21
Quelle: EOS
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
EOS 2010 � EOS tooling applications� Augustin Niavas Page 22
What is DMLS for tooling?
EOS 2010� EOS tooling applications� Augustin Niavas Page 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 24
DMLS with Direct Tool push on tooling design
— 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
Today Direct Tool means advanced tooling
Schematical comparison between conventional cooling and conformal cooling channels
Source: EOS
EOS 2010� EOS tooling applications� Augustin Niavas Page 25
What means conformal cooling?
Source: EOS
— 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
— 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
Advanced tooling
Conventional tooling
EOS 2010� EOS tooling applications� Augustin Niavas Page 26
Quelle: EOS
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 / 1.2709 steel
• Injection moulding series tooling, engineering parts
— EOS StainlessSteel GP1
• Stainless steel 17-4 / 1.4542
• Functional prototypes and series parts, engineering and medical
EOS 2010� EOS tooling applications� Augustin Niavas Page 27
Quelle: EOS
With CobaltChrome SP2 EOS has a material tuned to the dental industry’s requirements
— EOS StainlessSteel PH1
• Hardenable stainless steel
• Stainless steel 15-5 / 1.4540
• 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)
EOS 2010� EOS tooling applications� Augustin Niavas Page 28
Quelle: EOS
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
EOS 2010� EOS tooling applications� Augustin Niavas Page 29
Definition: EOS MaragingSteel MS1 - high performance steel for series tooling and other applications
— 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
Characteristics, applications, status
Injection mould insert with conformal cooling, built in EOS
MaragingSteel MS1
Source: EOS, Oase
EOS 2010� EOS tooling applications� Augustin Niavas Page 30
Properties: EOS MaragingSteel MS1 is a high performance steel for series tooling and other applications
— Mechanical properties as built• UTS: 1100 MPa• yield strength:1000 MPa• hardness: 33 - 37 HRC
— Mechanical properties after age hardening (6 hours at 490°C)
• UTS: > 1950 MPa• yield strength: > 1900 MPa• hardness: 50 - 54 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
Mechanical and physical properties
EOS 2010� EOS tooling applications� Augustin Niavas Page 31
Industry footprint and priority sectors for EOS
— 150 EOSINT M270 worldwide
— Approx. 25% of the systems are related to tooling applications
— Biggest amount of systems/company: 10
Aerospace Medical
Tooling
Source: EOS
EOS 2010 � EOS tooling applications� Augustin Niavas Page 32
— Hella
— Continental/ Siemens VDO
— Gillette / Procter&Gamble
— Sharp
EOSINT M 270 reference users in tooling business
Manufacturer (OEM‘s):
Automotive lighting and Electronic supplier
Production & R&D
Direct part, tooling & R&D
Direct part in production & tooling
Source: EOS
EOS 2010 � EOS tooling applications� Augustin Niavas Seite 33
How will DMLS be part of the future of the tooling industry?
EOS 2010� EOS tooling applications� Augustin Niavas Page 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 Seite 35
DMLS: Parts already in production, technology potential still growing and developing
Introduction Growth Maturity
Time
Sales
Decline
DMLS
High speedmilling
Electrical IMM
EDM
EOS 2010� EOS tooling applications� Augustin Niavas Page 36
The business development growths along 3 axis
— 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
Source: EOS
DMLS as referencetechnology
M2XX as serial production machine
Cooperations as improvementcatalysers
The three development axis
EOS 2010 � EOS tooling applications� Augustin Niavas Seite 37
DMLS advantages for injection moulding
EOS 2010� EOS tooling applications� Augustin Niavas Page 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 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
Source: PEP
PEP Project for ABS products (50.000 parts, Legrand electrical components): lower costs and reduced lead time
EOS 2010� EOS tooling applications� Augustin Niavas Page 40
Influence on the injection molding process
— Tempering system effectivity allows up to 60% cycle time reduction
— Better control of the process
— Optimised workload and machine costs saving
— Better quality of the product
Source: LBC, EOS, Spritzgießtechnik – Verarbeitung – Maschine – Periferie – Hanser Verlag, 2004
Cycle time diagram
Mould opening -ejection
Mould closing
Injection carriage in
Filling
Cooling time
Advantages in terms of productivity
EOS 2010 � EOS tooling applications� Augustin Niavas Seite 41
Breakeven analysis illustrates economical benefits of DMLS in comparison to conventional tooling
Costs & revenue
Quantity of products
Total r
evenue
Total c
osts c
onventional t
ooling
Total costs DMLS
Fixed costs DMLS
Fixed costs conventional tooling
Lower cycle time
Possible initial
additional costs with DMLS inserts
Q DMLS Q Conventional tooling
Profit
Source: Inglass, EOS
Advantages in terms of cost saving
EOS 2010� EOS tooling applications� Augustin Niavas Page 42
60%
25%
10%
5%
Mould temperature control
Hot runner choice
Process stability
Maintenance
Heating/cooling has the most important influenceon product quality
— 60% of defects on products come from wrong or not efficient mould temperature control
— 25% hot runner choice
— 10% process stability
— 5% maintenance
Source: EOS, GTT GmbH
Different factors influencing quality of product parts in injection moulding
Advantages in terms of product quality
EOS 2010� EOS tooling applications� Augustin Niavas Page 43
Positive effects on products and material consumption
— Lower scrap rate: advantages in terms of reducing costs can be quantify: 10.000 Euro for inserts – 500.000 parts, 2 Euro/product – 25% 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 will allow the manufacturing of lighter products with the same mechanical properties
Source: EOS
Example of quality issues on PP-T20 product. Conformal cooling allows drastic reduction of scrap rate
Core side (hot)
7.11 5.924.95
97
Cavity side (cold)
Core side (hot)
9.63 9.529.45
Conformal cooling
Conventional cooling
175
Advantages in terms of product quality
EOS 2010� EOS tooling applications� Augustin Niavas Page 44
Positive effects for products and 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
Advantages in terms in material consuming
EOS 2010 � EOS tooling applications� Augustin Niavas Seite 45
Hints to advanced tooling design
EOS 2010 � EOS tooling applications� Augustin Niavas Seite 46
Design recommendations (1)
If you need to split your channels, then take care
of balancing them.
Cool down critical area, reaching them with free form
shape
Follow the contour of your insert and keep distance to
surface/wall constant
Give preferences to smooth lines, avoid
right corners
Do not hesitate to “boost”your cooling system if
necessary
Source: LBC
EOS 2010� EOS tooling applications� Augustin Niavas Page 47
Design recommendations (2)
Source: LBC. EOS
— 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
250
250
Boundary box and cooling channel sections
190
EOS 2010� EOS tooling applications� Augustin Niavas Page 48
Design recommendations (3)
Characteristics, applications
Source: EOS
12 - 144 - 6
8 - 122 - 4 1.5 - 2 x b2 - 3 x b
4 - 80 - 2
cab
Distance betweencenter of holesand cavity
Centerline spacingbetween holes
Hole diameter(in mm)
Wallthickness of injection
moulding part(in mm)
— 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
EOS 2010� EOS tooling applications� Augustin Niavas Page 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 Seite 50
Example cooling lines (2)
Cool down critical area, reaching them with free form
shape
Follow the contour of your insert and keep distance to
surface/wall constant
Give preferences to smooth lines, avoid
right corners
Source: BBE, EOS
EOS 2010 � EOS tooling applications� Augustin Niavas Seite 51
Criteria of choice for inserts for successful testing of technology
EOS 2010� EOS tooling applications� Augustin Niavas Page 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 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 Seite 54
Conventional Tooling characteristics vs. Advanced Tooling characteristics
Qualitative comparison between the two different type of processes
Tempering system complexity
Canal cross section
Advanced ToolingtypeConventional Tooling
Material costs
Part size
Durability
Design flexibility (part complexity)
Excellent
Poor
Source: EOS
Product quality
Back-up
EOS 2010 � EOS tooling applications� Augustin Niavas Page 55
Applications examples: tool inserts
EOS 2010� EOS tooling applications� Augustin Niavas Page 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 57
DMLS reduces cycle time up to 42% in project childgobelet (Polymold)
— Solution • Hybrid tool, one cavity• DMLS tool insert with conformal cooling channels• Hardness: 52-54 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, 200.000 Products/year):circa 24.000 Euro *
Tool insert Polymold child gobelet: core
Source: EOS, Polymold, BKL, EOS
EOS 2010 � EOS tooling applications� Augustin Niavas Page 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 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 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
Cross section of the cooling channels with long hole shape:
- improves the cooling performance of the tool insert
- not manufacturable conventionally
Design advantages : - equilibrated linear coolant flow
- improved flow speed in the cooling channels
EOS 2010 � EOS tooling applications� Augustin Niavas Page 61
Particularity of the DMLS tool insert
Conventional cooling system (left), DMLS cooling channels (right)
Source: BKL, Polymold, EOS
Hardness tool insert: 52-54 HRC
High glossy polishfinishing
Tool insert for the manufacturing of child
cup, material EOS Maraging Steel MS1
(1.2709)
Hybrid design
DMLS manufacturing
Conventionalmanufacturing
EOS 2010 � EOS tooling applications� Augustin Niavas Page 62
Particularities of the plastic product
Productivity increase up to 70% Reduction of scrap rate
Ideal temperature distribution reduces
warpage in plastic product
EOS 2010 � EOS tooling applications� Augustin Niavas Page 63
Tooling video shows benefits for injection moulding
EOS 2010� EOS tooling applications� Augustin Niavas Page 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 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 mouldingblank
• Reduction of the volume of sintered material
— Benefits
• Hybrid approach saves costs of tooling insert
• Cycle time reduction: 35%
• Reduction of scrape rate
• 12.000.000 products manufactured Example of hybrid tool
Source: LBC
EOS 2010� EOS tooling applications� Augustin Niavas Page 66
Serial production tooling in production (more than 2 years)
Source: LBC
Examples of cooling lines and hybrid insert
— 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
EOS 2010� EOS tooling applications� Augustin Niavas Page 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
Source: Inglass S.r.l
Examples of cooling lines and hybrid insert
EOS 2010� EOS tooling applications� Augustin Niavas Page 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.
Source: Inglass S.r.l
Examples of cooling lines on hybrid insert
3,3002200180,00166Tradit.
3,0002200180,00160SLM
Machine and direct labor cost[€/pz]
Press machine [tonn]
Machine and direct labor cost per hour
[€/h]
Pieces / cycle
t CYCLE
[s]
Cost of molding process for the production of 250.000 parts
0.2267,0003,3002.0%Tradit.
0.0557,0003,0000.5%SLM
Waste for scraps [€]
Material cost / piece[€]
Molding process cost / piece[€]
% scraps
Waste due to scraps on production of 250.000 parts
DMLS - 117.750,00€
EOS 2010� EOS tooling applications� Augustin Niavas Page 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.
— Results:
• no burning defects on the injection gate,
• comparing to a similar part, cycle time was reduced from 128 down to 110 s.
Source: Inglass
Cost saving DMLS
- 135.668,00€
4,0531000114,001128Tradit.
3,4831000114,001110SLM
Machine and direct labor cost[€/pz]
Press machine [tonn]
Machine and direct labor cost per hour
[€/h]
Pieces / cycle
t CYCLE
[s]
Cost of molding process for the production of 150.000 parts
0.3877,04,0533.5%Tradit.
0. 0527,03,4830.5%SLM
Waste for scraps [€]
Material cost / piece[€]
Molding process cost / piece[€]
% scraps
Money waste due to scraps on production of 150.000 parts
EOS 2010� EOS tooling applications� Augustin Niavas Page 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
Source: BKL-Lasertechnik
Tool inserts for lipstick lids
EOS 2010� EOS tooling applications� Augustin Niavas Page 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)
• 40.000 parts per year
• Inserts costs: 3.250 Euro
• Cost saving: 19.444 Euro
• Amortisation time: 2 months
• High Injection moulding machine hours saving (555 hours that is from 1000 hours to 444 hours)
• Better product quality
Source: LBC
Tool insert for injection moulding
EOS 2010� EOS tooling applications� Augustin Niavas Page 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
• 180.000 parts manufactured in serial production
Source: LBC
Tool insert for die casting
EOS 2010� EOS tooling applications� Augustin Niavas Page 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)
Source: Ecoparts
Tool insert reparation: before (under) and after the use of DMLS (upper).
EOS 2010� EOS tooling applications� Augustin Niavas Page 74
Integration of DMLS inserts into machined tool baseallows 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
Source: FIT
Production mould with inserts in EOS MaragingSteel MS1, built on EOSINT M 270
EOS 2010� EOS tooling applications� Augustin Niavas Page 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
Source: General Pattern Inc
Modular tool for a guide adaptor
EOS 2010 � EOS tooling applications� Augustin Niavas Seite 76
EOS®, EOSINT®, DMLS®, DirectPart®, DirectTool®, DirectPattern®, DirectCast® and Alumide® are registered trademarks of EOS.
Source: EOS
EOS GmbH
Electro Optical Systems
Robert-Stirling-Ring 1
D - 82152 Krailling
Germany
Tel: +49 89 893 36 -0Fax: +49 89 893 36 -285 eMail: [email protected]: www.eos.info
www.eos.info