Source:  MoldMaking Technology

“The process of building conformal cooling inserts can be generally broken up into four steps: 1) simulating the molding process, 2) insert design and optimization, 3) 3D direct metal laser melting, and 4) post processing. Simulation software in the first step allows tool designers to visualize flow capabilities and thermal properties that can cause mold deformation prior to actual production. Cavity block or core block inserts then can be designed with conformal water lines in place, based on simulation results. The layer-by-layer 3D-printing that comes next not only can be completed in a number of materials that match conventional tool steels, but the resulting built-in channels will exhibit outstanding geometric flexibility. Post-processing tasks include stress relief and heat treatment, using EDM to machine the part from its platform base, polishing the part surface, adding water lines, and inspection.”

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