Manufacturing stories - Metal tooling

Better injection molding thanks to 3D printed inserts

A Use Case

for Additive Manufacturing

The Xact Solution to better tooling

Thanks to additive manufacturing, injection molders and mold makers can create complex geometries that are difficult or impossible with traditional CNC machines. 3D metal printing is a useful tool in their toolbox

Work faster
Cheaper to produce
Increase efficiency

Metal printers

Injection molds

Injection molding molds are an excellent application for additive manufacturing . With a simple design adjustment, often of an existing part, you can: conformal cooling channels are added. Unlike traditional, straight cooling channels, conformal cooling channels follow the contours of the workpiece or mold. This significantly reduces the cycle time. Since cooling approx 80% of the total cycle time matters, the impact can be enormous.

Use Case: Gate insert

This insert required a lot of water and cooling, but the space was so small that the only solution using traditional manufacturing techniques was to insert a fragile piece of steel, because the walls were too thin. During the injection molding process in a high-pressure, fast-moving system, the steel often broke and had to be replaced regularly. This meant that the production line often had to be shut down.

Of metal 3D printing it became possible to make the walls of the insert heavier, while still fitting in the same space, including conformal cooling channels . This solution made it possible to cool the insert more efficiently, while preventing the inserts from breaking. With multiple molds in the factory, cycle time is reduced by 10%.

Additive manufacturing can be a great help to mold makers when designing complex models. When mold parts are 3D printed, these can internal functions such as conformal cooling channels. This adjustment can lead to faster, cheaper and more efficient production processes that require less material.

3D printing makes it possible complex geometries that are not feasible with traditional CNC machining methods. Furthermore, mold design and production can be done by the same operator and sometimes even on the same day.

The printed parts have properties equivalent to those of conventionally made parts, with a density of more than 99.5% of the theoretical density, tolerances of +/- 0.2% and a fine finish. These densities ensure optimal hardness .

Reduce cycle time

By placing the curved water channels (conformal cooling) exactly where the hot spots or complex shapes are located, you can shorten the mold cycle time with targeted cooling.

On-Site Production

The ability to execute an entire production workflow quickly and in a compact space. No more waiting for steel to build your mold. Print parts in hours, not weeks, and increase throughput.

Quality check

Printing inserts with conformal cooling can reduce distortion and hot spots in molds, resulting in higher quality parts and fewer rejects.

Design freedom

The freedom to place internal structures and channels close to the cavity for faster cooling times when injection molding, without concerns about rust or compromising the required A1 surface finish through the use of Uddeholm's Corrax material.

AM Corrax® powder

Uddeholm AM Corrax® is a stainless steel specifically designed for additive manufacturing, offering a unique set of properties that make it the ideal choice for tools that require both high corrosion resistance as great hardness require. These properties make it perfectly suited for plastic molds, including demanding applications such as molds for medical parts, corrosive plastics (such as PVC) and rubber parts.

A. M. Corrax provides excellent polishing capabilities for a smooth and glossy finish, ideal for complex tools. The excellent corrosion resistance also aids in the design of complex conformal cooling channels by reducing the risk of blockages, oxide layers that reduce cooling efficiency, or cracking due to corrosion.

Thanks to its favorable chemical composition A. M. Corrax easy to process in additive manufacturing, which ensures top printing results and excellent material properties.

Uddeholm AM Corrax offers several advantages over most additive manufacturing tool steels:

Flexible hardness from 36 to 50 HRC, achieved by aging at 425-600°C
Good dimensional stability during aging
Excellent polishability
No hard "white" layer after EDM processing
Excellent corrosion resistance
Easy to machine with additive manufacturing equipment and SLM technology

Corrax - technical sheet

making 3D metal printing accessible to everyone

Xact Metal makes it possible for industrial companies to benefit from the benefits of high-quality 3D metal printing at an attractive price, and breaks the idea that additive manufacturing in metal is only for large companies.

Contact us for a try & buy

Contact the SEIDO team for a feasibility study based on your 3D files. Thanks to print simulations and accurate ROI calculations, we can quickly determine the added value of metal printing for your industry.