Unlocking New Horizons in Manufacturing: The Impact of Metal Additive Manufacturing on Production Efficiency

In this week's edition of our newsletter, we focus on a transformative aspect of metal additive manufacturing (AM) — conformal cooling. By leveraging cutting-edge technologies like laser powder bed fusion (LPBF) 3D metal printing, we are not just advancing manufacturing efficiency but also delivering superior quality and performance through innovative cooling solutions.

Case Study 1: ABB's Breakthrough in Tooling Inserts ABB, a global leader in power and automation technologies, collaborated with Nikon SLM Solutions to redesign their tooling inserts using LPBF. Traditionally, injection molding tools used for high-volume components, such as cabling grommets, had no cooling inserts, resulting in longer cycle times — about 60 seconds per cycle, with 30 seconds dedicated to cooling the thermoplastic elastomer (TPE).

By incorporating conformal cooling channels optimized for Nikon SLM? technology, ABB achieved a drastic reduction in cooling time to just six seconds. This change reduced the overall cycle time to 14.7 seconds, significantly increasing production efficiency. The conformal cooling channels, designed to follow the contours of the insert closely, enabled rapid and turbulent water flow, ensuring uniform cooling and improving product quality.

Case Study 2: Oskar Frech's Advances in Die-Casting Oskar Frech GmbH & Co. KG, known for its die-casting machinery, has also tapped into the potential of LPBF. Utilizing their SLM?280 machine, Frech optimized die-casting mold inserts with internal conformal cooling channels. This innovative design cut cooling times by 60%—from 12 to just five seconds—and reduced overall cycle times by 12%.

The precise placement of cooling channels through additive manufacturing allows efficient tempering of cores, wipers, and anvils, enhancing the surface quality of die-casting components and extending mold service life. The improved cooling efficiency results in fewer defects like pores and cavities, leading to higher quality products and more reliable production processes.

Beyond the Case Studies: Broader Impacts of Conformal Cooling

1. Enhanced Production Efficiency: Conformal cooling dramatically reduces cycle times by ensuring faster and more uniform cooling of molded parts. This efficiency gain translates directly into increased production rates, enabling manufacturers to meet higher demand without compromising quality.
2. Improved Part Quality: By maintaining uniform cooling, conformal cooling channels help minimize internal stresses and warping in molded parts. This consistency leads to better dimensional accuracy and surface finish, which is critical in industries such as automotive and aerospace where precision is paramount.
3. Energy Savings: Faster cooling times not only boost production rates but also reduce energy consumption. Shorter cycle times mean that machines spend less time in the cooling phase, lowering overall energy usage and contributing to more sustainable manufacturing practices.
4. Flexibility in Design: The ability to create complex cooling channels that conform to the geometry of the part allows for more innovative and efficient designs. This flexibility can lead to better-performing products and new applications for molded parts.

Looking Forward: The Future of Conformal Cooling in Manufacturing The success stories of ABB and Oskar Frech highlight the tangible benefits of integrating conformal cooling through metal additive manufacturing. As the technology continues to evolve, we anticipate even greater efficiencies and innovations in cooling solutions.

At Howco, our commitment to embracing advanced manufacturing techniques like LPBF ensures we remain at the forefront of industry advancements. Our expertise in critical application solutions allows us to deliver exceptional value to our customers, improving their production efficiency and product quality.

Subscribe to our newsletter to stay updated on the latest developments in conformal cooling and how Howco is leveraging these advancements to revolutionize manufacturing. Join us on this exciting journey into the future of efficient and high-quality production.

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