What is Conformal Cooling in Injection Molding?

Traditional cooling mechanisms designed in straight lines only provide coverage to a partial outline of the part’s geometry in the mold. Conformal cooling lines are 3D printed to reach all the unique contours of a part’s geometry in the mold or tooling inserts. Conformal lines are therefore less restricted as to where they are placed in the tooling.

Temperature control is crucial in injection molding, as the mold heats up as molten plastic is injected into it. With conventional cooling techniques, the temperature of the mold often rises over the threshold for ejecting a successful part–wasting time and money while the mold cools to an acceptable temperature for part ejection. Conformal cooling, however, maintains a nominal temperature, allowing for a more rapid temperature reduction so that the overall cycle times are reduced each time the mold opens and closes.

3D Design and Printing for Conformal Cooling

When considering conformal cooling as a solution, we analyze both the part and associated mold details to identify which would benefit most from conformal cooling inserts. These details could be mold cores, cavities, slide faces, lifters, or any combination of these. We then design a cooling strategy so that optimum cooling conditions are realized. This process often makes feasible the ability to cool areas not adequately addressed such as radiused corners or tall or thick ribbed details. Above all, it allows for the cooling lines to “conform” to the actual part geometry. The result creates opportunities for broader process windows and process controls, resulting in reduced overall cycle time.

3D printing and conformal cooling create endless possibilities for engineers engaged in industrial manufacturing. Some consider conformal cooling to be one of the most important uses for 3D printing today, highlighting two of this technology’s greatest benefits: freedom in design, and the ability to create sophisticated geometries previously impossible via traditional manufacturing.

Although we provide a variety of services, our engineers typically use Direct Metal Laser Melting (DMLM) to open up more opportunities in design and production for examples like traditionally drilled machined water lines. For that type of project, conformal cooling makes a tremendous difference in production as the process allows lines filled with water to follow the complex shape–including cross sections–of each part.

DMLM additive manufacturing technology makes it possible to customize your small-to medium-sized parts and inserts in days rather than the weeks or months associated with traditional manufacturing. This metal 3D printing process expands freedom in design-driven manufacturing, produces extremely high-quality, repeatable injection molded parts, and accelerates production on every level, improving time to market.

When Should I Use Conformal Cooling?

We recommend conformal cooling (especially for plastic injection molding) when:

• Cycle times are longer than predicted or budgeted.
• The dimensional integrity of your molded parts is non-conforming.
• Traditional manufacturing methods are limiting your mold’s cooling features.
• Improper cooling is causing deformed parts, resulting in excessive scrap costs.

Shapeways Process

Our engineers performed a recent study, further validating this process. In the example studied, results demonstrated a 69% reduction in cooling time. Software analysis also verified that the modified sample cooling channels revealed a more uniform temperature distribution when compared to the original cooling design.

During actual manufacturing environments, our customers running 70-80 parts an hour with traditional cooling lines or channels typically increase their output to an impressive 140 parts an hour with 3D printed conformal cooling inserts.

Shapeways for Conformal Cooling

The impact and efficiency of conformal cooling can transform production for your company, and accelerate growth. In 2022, Shapeways further expanded its traditional manufacturing capabilities with the acquisition of Linear AMS, an expert in injection molding known for innovative solutions like conformal cooling. Linear’s true, consultative approach made them a trusted partner in solving the toughest manufacturing challenges and Shapeways has continued with that legacy.

The post Using 3D Printing in Injection Molding with Conformal Cooling appeared first on Shapeways Blog.

What is Conformal Cooling?

Conformal Cooling is a manufacturing technique that involves creating cooling channels or passages within a tool or mold that conform to the shape of the part being manufactured. Conformal cooling is most often used in plastic injection molding to reduce cycle times and improve part quality.

How Does Conformal Cooling Reduce Mold Cycle Time?

Conformal cooling provides precise heat regulation, optimizing cooling rates, and significantly reducing cycle times. Traditional cooling mechanisms designed in straight lines only provide coverage to a partial outline of the part’s geometry in the mold. Conformal cooling channels, however, are 3D printed to reach all the unique contours of a part’s geometry in the mold or tooling inserts.
Temperature control is crucial in injection molding, as the mold heats up when molten plastic is injected into it. With conventional cooling techniques, the temperature of the mold often rises over the threshold for ejecting a successful part–wasting time and money while the mold cools to an acceptable temperature for part ejection. Conformal cooling maintains a nominal temperature, allowing for a more rapid temperature reduction so that the overall cycle times are reduced each time the mold opens and closes.

By implementing conformal cooling, businesses can achieve remarkable results in terms of increased productivity and profitability. With cycle time savings, machinery and resources are freed up to produce other parts, unlocking manufacturing capacity.

In addition to these benefits, the efficient heat regulation provided by conformal cooling significantly improves overall efficiency. By optimizing cycle times, companies can allocate resources more effectively and avoid the need for additional equipment.

Materials Advanced by Conformal Cooling

Conformal cooling plays a pivotal role in improving quality of part production with a variety of materials, including nylon. Mold temperatures are quickly and subtly adjusted, allowing for precise control.
For materials that are heated to extremely high temperatures and require a more contracted cooling process, our engineers are also currently exploring variations like ‘conformal heating,’ using hot oil instead of water to cool molds when dealing with high-temperature materials.
Our engineers typically 3D print the cooling inserts in materials like Steel. Advanced technology like Direct Metal Laser Melting (DMLM) opens up endless opportunities in design and production making it possible to 3D print lines that follow the complex shape–including cross sections–of each part.

Avoiding Dimensional Issues

Quality or dimensional issues often stem from an inability to control the thermal delta (or heat difference) across the expanse of a part. High scrap rates, warpage, and distortion are all typical symptoms of uneven cooling. Conformal cooling helps maintain the dimensional integrity of the part, ensuring consistent quality and reducing waste.

While a typical customer may be running 50 to 80 parts an hour traditionally, with 3D printed conformal cooling inserts they can look forward to upwards of 140 parts per hour, making a huge difference in productivity for every manufacturing job.

What are Applications for Conformal Cooling?

There are a variety of parts and features that can benefit from using conformal techniques, across multiple industries. Objects like cups with handles, are a great example. Conformal cooling minimizes the potential for dimensional issues like shrinkage, distortion, warpage, and loss of structural integrity. Instead, manufacturers enjoy uniformity in parts, consistent quality for high-performing parts, and reduced waste during production.
To identify suitable applications for conformal cooling software like Moldex3D can be used for comprehensive analysis of molds, simulating flow patterns, cooling efficiency, and identifying potential issues like hot spots. This powerful software helps provide detailed data and visualizations, enable fine-tuning of conformal cooling parameters, and enhances part quality—allowing manufacturers to optimize production efficiency and produce larger volumes of parts.

Why do Manufacturers Use Conformal Cooling?

Manufacturers gain a significant edge in today’s competitive landscape with the ability to identify the correct applications and uses for conformal cooling. Efficient temperature regulation, reduced cycle times, improved part quality, and increased productivity are just some of the benefits offered by conformal cooling.
By leveraging the transformative potential of conformal cooling, businesses can thrive in a competitive market, setting new standards for productivity and excellence. See how Shapeways can help manufacturers with their conformal cooling needs.

Shapeways for Conformal Cooling

The impact and efficiency of conformal cooling can transform production for your company, and accelerate growth. In 2022, Shapeways further expanded its traditional manufacturing capabilities with the acquisition of Linear AMS, an expert in injection molding known for innovative solutions like conformal cooling. Linear’s true, consultative approach made them a trusted partner in solving the toughest manufacturing challenges and Shapeways has continued with that legacy.

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Founded in 2007, Eastern Rail Corporation built a reputation on designing sustainable, high-quality solutions for the Metro Rail infrastructure in the US. For a specific component—an insulator that isolates the electrified third rail in underground subway systems–Eastern Rail needed to update the material to meet safety standards. A switch to Polyphenylene Sulfide (PPS) subsequently required a reevaluation of the existing mold. To tackle this issue, Eastern Rail approached Linear AMS, a Shapeways Company, seeking partnership in creating an innovative solution to enhance functionality and efficiency.

Eastern Rail is a long-standing customer, supporting transit agencies in metropolitan areas like New York City, Washington, D.C., and Miami, where urban rail systems frequently operate in underground tunnels. Such an environment demands components with specific dielectric properties, safeguarding against unwanted electrical charges and allowing for more effective management of underground train lines.

Incorporating Advanced Cooling Technology

Injection molding manufacturers often face challenges related to long cycle times, part quality, and overall efficiency. Conformal cooling technology specifically resolves these problems. Relying on 3D printing for customization and efficiency, conformal cooling adapts to fit into industrial molds. 

In contrast to conventional methods, which are restricted to machining in straight lines, conformal lines are designed to follow the shape of the part itself–leading to a more consistent temperature throughout the part’s cooling stage. This means that parts are less likely to warp, while also cooling up to 50% faster. With conformal cooling, manufacturers can reduce their cycle time and increase their throughput, all while improving part quality. 

For Eastern Rail, integrating this technology produced more consistent temperatures in tooling, leading to more efficient production cycles, satisfying stringent requirements for reliable and efficient rail systems.

Improving Tooling for Complex Materials

Initially, Eastern Rail encountered challenges due to the complex part design and core mold features, combined with the nature of Xencor PPS LGF-3045, a 45% long-glass, fiber-reinforced Polyphenylene Sulfide (PPS).

While providing beneficial properties like heat resistance and durability, PPS also presents manufacturing difficulties. Linear performed a comprehensive analysis, revealing that Eastern Rail’s existing tooling with conventional cooling–in combination with a PPS material–would not produce a moldable part.

“I was aware a new approach would be necessary with the change in material,” said Mickey Morales, CEO of Eastern Rail. “After working with Linear for the past decade, I was confident in their engineering expertise and knew they were capable of delivering the dynamic solution this project needed.”
To address these issues, Linear and Eastern Rail worked side-by-side for months in prototyping and testing, experimenting with molds and the integration of 3D printed conformal cooling lines.

Upon initial review, the team suggested making the change to a steel mold over aluminum for production volumes. The PPS material is highly corrosive and would deteriorate the aluminum mold. Transitioning to a steel mold also opened up the possibility of using conformal cooling to allow for better thermal control. Additionally, based on the molding temperature requirements of PPS, the team determined hot oil would be necessary to maintain tool temperature, as opposed to water which is more commonly used.

“The shift to steel molds significantly transformed our approach, working much better with the unique characteristics of PPS and the need for a precise, controlled molding environment,” said John Tenbusch, Director of Automotive Sales at Shapeways.

“After working with Linear [A Shapeways Company] for the past decade, I was confident in their engineering expertise and knew they were capable of delivering the dynamic solution this project needed.”

Mickey Morales, CEO of Eastern Rail

Reducing Cycle Times & Improving Part Quality

The introduction of conformal cooling was highly effective, yielding a remarkable improvement in efficiency after Linear introduced steel tooling. Implementing conformal cooling led to a design adjustment that significantly cut costs. Interchangeable inserts, usually requiring three cores, were reduced to just one.

“We had to incorporate cooling one way or another,” said David Dickerson, Manager of Client Services at Shapeways. “Without conformal cooling, we couldn’t have made the interchangeable parts we needed for the various sizes of the insulator.”

With the new steel molds and conformal cooling inserts, the Linear team was able to reduce the cycle time from 181 seconds to 138 seconds, reflecting a 23% improvement. Reduced production time allows for more parts to be made, lowering both piece cost and overall program cost, without sacrificing part quality. The more even, controlled temperatures also led to the production of higher-quality, more reliable parts.

While the initial prototyping and testing phase required significant time and financial investment, the cost savings over the long term more than justified the upfront expenditure. The enhanced material durability, lower maintenance needs, and increased production speeds collectively contributed to significant long-term economic advantage for Eastern Rail.

“While we encountered a few obstacles during our journey, Linear’s team of experts was again able to provide a highly engineered solution while providing cost-saving benefits,” said Mickey Morales, CEO of Eastern Rail.

Aligning with Regulatory and Environmental Considerations

Eastern Rail’s openness to new solutions enabled improvements with both short and long-term benefits, meeting industry-specific needs while maintaining a commitment to environmentally friendly materials and regulatory compliance.

This case study offers useful problem-solving insights for issues related to materials, tooling, and cooling. These solutions may be applicable to other manufacturing sectors as well. Overall, this project showcases the value of teamwork, innovation, and excellence in manufacturing

Find out more about how Shapeways can collaborate with your company.

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We’re excited to introduce the first annual Shapeways Manufacturing Week (SWM Week), taking place from October 2-6, 2023. SWM Week offers an action-packed schedule of learning for engineers, designers, and manufacturing professionals. 

Interact with thought leaders, gain valuable insight to help redefine your approach to manufacturing, and take advantage of exclusive promotions. Shapeways brands MFG and Linear AMS will also share expertise on business evolution and innovative applications for additive manufacturing. 

Whether you’re an independent manufacturer, designer, or an industrial engineer, join us to connect with peers and leaders in your field! SWM Week is entirely virtual–just complete your registration here. 

Unable to attend live? Register for the events you’re interested in, and we’ll send you the recordings afterward.

Schedule of Events

Monday, October 2

Day 1 / Business Evolution Day – As we kick off the first day of SWM Week on October 2 with Business Evolution Day, the focus is on independent manufacturers, and how they can ramp up their business. Topics will include website optimization and use of social media platforms to engage with target audiences.

Learn from independent CNC manufacturers as they discuss strategies for business growth and offer actionable advice for taking your company to the next level. Whether you’re just starting a shop, or work at an established company, this event serves as a practical guide for modern business development strategies.

Tuesday, October 3

Day 2 / Designer Day – Designer Day is focused on designers, engineers, inventors, and innovators. 

Be sure to register for the informative tutorial with our 3D design partner CADmore, as they share advanced strategies for design. 

On the traditional manufacturing side, don’t miss ETHO founder, Dave Fustino as he outlines the process from concept to mass production, following design for manufacturing principles. Whether you’re an engineer, designer, or industry professional, this event offers valuable insights and actionable tips.

Wednesday, October 4

Day 3 / Traditional + Additive Manufacturing – Scheduled for October 4, Traditional + Additive Manufacturing Day is a chance to hear how these methods can complement each other in everything from rapid prototyping to full-scale production, and in other surprising use-cases too. Industry leaders Harold Sears, David Tucker, and John Tenbusch will lead a panel discussion, sharing their expertise on how to select the best manufacturing strategies. 

Whether you’re interested in exploring end-to-end manufacturing solutions, conformal cooling showcases, or you’re just eager to ask your top manufacturing questions, this day is designed to expand your understanding of manufacturing possibilities.

Thursday, October 5

Day 4 / 3DU Day – Join us for 3DU Day on October 5, as we learn about additive manufacturing’s role in education and explore the growth of 3D printing in the education sector.

Register to hear from Shapeways SVP of Technology, Ajay Raina, and Engineering Tech Lead, Joe Estefane, as they explore the fascinating intersection of Generative AI and 3D printing, and delve into how AI is revolutionizing development and production processes.

We’re also offering special promotions and contests for designers and engineers. As an added bonus, the Shapeways educational discount is also increased from 15% to 20% for the month of October!  

Friday, October 6

Day 5 / Shapeways Manufacturing Day – Don’t miss out on the exciting conclusion of Shapeways Manufacturing Week on Day 5. Register for a Fireside Chat featuring Shapeways CEO Greg Kress, AMUG and Layered Manufacturing and Consulting President Shannon VanDeren, and moderator Amanda Harrell, GM, eCom & VP, Marketing for Shapeways. This discussion will cover industry trends in both traditional production and 3D printing, while also discussing the future of AI in manufacturing. 

Whether you’re in business, design, or academia, you won’t want to miss this comprehensive wrap-up to a week focused on manufacturing’s evolving landscape. Mark the date–the Fireside Chat is a must-attend event!

SWM Week Contests and Promotions

Be on the lookout for special prizes, promotions, and exclusive savings during SWM Week. For instance, you can nominate an engineer in our Engineer Appreciation Contest for the opportunity to receive a $500 Amazon gift card—or enter our Design Contest for a chance to receive $100 in 3D printing credit for High Definition Full Color.

Don’t miss the chance to participate in a week filled with rewarding opportunities and events, exciting contests, and exclusive promotions. For complete event details and to register, visit the Shapeways Manufacturing Week website.

The post Your Guide to Shapeways Manufacturing Week 2023 appeared first on Shapeways Blog.

Developing Knowledge of New Technologies

3D Printing is a technology that continues to grow and is used not only for prototyping and manufacturing but to facilitate innovation in a multitude of different fields. Developing the skills to use it not only open the door to future jobs but also allows for new levels of thinking and potential as the limits of what is possible to create are pushed.

Refining Creativity, Design and Problem Solving Skills

It also calls for students to develop key skills in design, allowing them to advance their creativity and engage their imagination. By observing an object that they have designed and 3D printed, they are able to make tests, refine their work and learn by trial and error, enabling students to participate more fully in their own learning and develop problem solving skills. It also gives them the tools and confidence to pursue new ideas.

Enabling Visual Learning

Teachers can use 3D printing to create tangible aids and illustrate complex concepts or objects that allow for students to engage more directly with whatever they are learning about and this extends to virtually any subject in school. History students can observe a specific 3D printed artifacts. Geography students can explore 3D printed maps. In Biology, a 3D printed model of a heart gives students a chance to investigate from all angles and gather and retain information they might not from a 2 dimensional image.

How 3D Printing Technology Can Successfully Be Introduced in Schools

In the last few years the cost and size of machines has dropped making them more accessible to schools. The biggest challenge is equipping teachers with the skills needed to apply this technology in the classroom. More and more guides, tutorials and project ideas for educators are being put in place online and accompanying specific machines. If 3D printing is to successfully integrate classrooms it is crucial that teachers are given the tools they need to understand it themselves. 

Because the 3D printing world is aware of its growing importance in the classroom, many machines are being built to suit younger users. What’s important is selecting the right machines to best fit a school’s curriculum.

When introducing printers is not possible, tools like 3D printing pens allow students to develop a basic understanding of 3D by creating their own sculptures. 3D printing services like Shapeways can also be utilized to give students access to high-end technology without the cost associated with buying a printer.

Despite the challenges of integrating a new technology into schools it is no question that 3D printing is becoming an undeniable asset in education. It not only invigorates the learning process but provides students with invaluable skills and opportunities to expand the realms of possibility for developing minds.

Want to utilize 3D printing for your educational project? Shapeways will help you bring industrial grade printing to your next big project.

The post The Future of 3D Printing In Education appeared first on Shapeways Blog.

Illustrating Complex Concepts

One of the biggest uses of 3D printing in University classrooms is to print models as visual and tactile learning aids. Ognjen Miljanic, a Professor at the University of Houston 3D printed large scale models of crystal molecules that would typically be too small to see with a naked eye. This allows for more information to absorb faster than with two dimensional models or text explanations in any area of study. 

Prosthetics

Duke University’s eNable, a club made up of engineering students, work to create dynamic prosthetics for three different recipients per school year. Starting with open source files such as Unlimbited Arm, K1 Hand and Gripper Thumb Hand they modify the designs to be appropriate for each specific recipient. For Brooke, a pharmacy school graduate, students modified the grip between thumb and index so that she could pinch skin for subcutaneous injections. Many other Universities are using 3D printing to create prosthetics, as a way to both give back to their communities and continue innovating in the field.

Robotics

3D printing typically serves to create parts and prototypes in robotics and engineering but students at the Wyss Institute at Harvard University used a multi-material printer to create an entire soft-bodied jumping robot. They used a nine layer material transition from rigid core components to soft exterior components in a single print session. This results in a high level of durability that allows for the improvement of a wide range of robotic and engineering designs. 

Paleontology

When 45% of the Dreadnoughtus schrani dinosaur’s bones were uncovered between 2005 and 2009 by professor Dr. Kenneth Lacovara’s team from Drexel University, a virtual mount of the dinosaur’s skeleton was created by 3D scanning each bone. Using these 3D scans, a doctoral candidate Kristyn Voegele from the Drexel College of Arts and Sciences joined with the College of Engineering to 3D print models of the dinosaur’s bones and muscles to further study how the Dreadnoughtus schrani moved. The use of 3D printing makes crucial improvements in the way extinct creatures can be studied because it allows them to be explored in a physical context, rather than simply digital.

Art

Noah Gunther from Lawrence University integrated 3D models and a 3D environment he created to produce an installation called Mystery Ocean that deals with the area between our physical world and the computer world.

Creating Accessibility to 3D Printing Technology

The Technical University of Berlin recently opened a 3D printing cafe that is available for use to help students and non-students alike familiarize themselves with 3D printing technology. The cafe uses mostly recyclable raw materials to maintain sustainability and be as environmentally friendly as possible.

Optimizing the 3D Printing Process

The use of 3D printers in universities also gives students an opportunity to improve the process themselves by making the devices run more efficiently. At MIT, researchers replaced the pinch-wheel design on a desktop 3D printer with a screw design that pulls the textured filament to the printhead faster than any other printer on the market. This assures that the technology will continue to improve to make printing faster and more efficient to industries that rely on it.

These are a fraction of the projects utilizing 3D printing in Universities and the presence of this technology can only expand and open new avenues of innovation in future generations of students. Learn how Shapeways can help you with your education projects. 

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