Schuler's use of 3D printing technology to produce prototype molds that allow coolant passages to conform to a more perfect net shape ensures that all parts of the assembly can be quickly cooled at the same speed for better part characteristics. The manufacture of hot stamping dies is almost destined to become a new application area of ​​3D printing technology.
Hot stamping dies require coolant passages to ensure that the temperature of the annealed sheet metal is quickly reduced below 200 degrees Celsius. In the past, it was often necessary to make coolant passages by directly drilling holes in the mold, so that it was almost impossible to create continuous positions on the surface, especially for molds of complex shapes. Now, with the help of 3D printing technology, Schuler is making prototype molds that will allow the passageway to conform to a more perfect net shape. This ensures that all parts of the assembly can be quickly cooled at the same speed for better part characteristics.
The 3D printed combination mold has the same mechanical properties and technical characteristics as the actual mold to a degree as high as 95%.
“Optimized cooling channel geometry ensures mold cooling is more uniform and efficient,†explains Udo Binder, head of Schuler’s smart tooling solutions group. “The 3D printing technology has brought new possibilities for the design of cooling channels, which helps us to design molds that can uniformly cool.†Schuler uses laser welding as a stacking manufacturing process. The base material is the same steel as the conventional hot stamping tool – but it is sprayed one after the other in powder form and connected by laser welding. The composite mold thus produced has the same mechanical properties and technical characteristics as the actual mold to a degree as high as 95%.
The substrate is a tool steel in the form of a powder that is sprayed one by one and connected by laser welding. Previously, Schuler has determined the ideal process parameters and the optimum composition of the powder material through comprehensive inspections. It then performed various tests on the composite mold to determine the tensile strength and specific gravity. Schuler is currently testing wear and mass production. “Manufacturing hot stamping molds is almost destined to become a new application area for 3D printing technology,†concludes Udo Binder, head of the business unit. "We are ready."
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