NEWS


LASER SINTERING IMPROVES MOULD COOLING FOR CAR PART MAKER


Czech-based additive manufacturing company Innomia has designed a new tool insert with direct metal laser sintering (DMLS) for creating the central front armrest in a Škoda car. Innomia used EOS technology to implement conformal cooling in the mould, reducing injection moulding time by 17 per cent and improving component quality. Direct metal laser sintering is an additive


technique that builds up a part, layer by layer, by sintering metal powder with a laser. Innomia’s engineers supported automotive supplier Magna in optimising cooling of the mould in the project for Škoda. Injection moulding of the glass fibre reinforced


plastic component is difficult, as uniform dissipation of heat throughout the tool has a significant effect on minimising distortion and improving component quality as it solidifies. Moreover, temperature control


– the elevated humidity accelerated corrosion, necessitating costly, intensive cleaning of the mould every one to two weeks. Designers from Innomia developed the new


tool insert cooling system with integrated conformal cooling channels. This is an established application using DMLS technology and one that only additive manufacturing can achieve. An EOSINT M 270 system from EOS was used to sinter Maraging Steel 1.2709 metal powder. Innomia was able to increase the hardness


plays a major role in minimising the production cycle time, as the quicker heat is removed, the sooner a component can be ejected and the next one produced. The tool insert previously used was made of


competition in the European automobile industry


There is stiff


beryllium-copper alloy, which has a high thermal conductivity. Cooling was possible from one side of the insert only, so temperature distribution was uneven. As the temperature differential between the water and the mould was high – around 120°C


through post-treatment to more than 50 HRc, leading to high wear resistance and low maintenance costs. Luboš Rozkošný, CEO at Innomia, explained: ‘The DMLS process enabled us to manufacture an extremely durable component, while at the same time successfully retaining the proven advantages of AM in terms of design flexibility.’ The temperature distribution and associated heat dissipation


are now substantially more homogeneous. Since the heat leaves both the tool and the component more quickly, a water temperature of 60°C is now sufficient for cooling. The insert surface temperature does not rise beyond 90°C and the consequent fourfold reduction in temperature differential has removed the air humidity problem and reduced energy consumption.


Automotive supplier installs smart laser welding solution


Prague-based MediCom and laser beam shaping specialist, Limo, have developed a laser welding solution for a large German automotive supplier designed according to the concept of Industry 4.0. Limo developed a laser head


software program that controls the process and monitors the welding operation. Industry 4.0 is a German concept referring to the fourth industrial revolution, whereby manufacturing equipment is interconnected via the internet to monitor the production process. For each component, the


system signals whether the individual welding operation


8


– including all of the welding parameters – was OK or not OK. The closed-loop control system gives fully in-line quality control, and the system offers machine-to-machine communication via a fieldbus. The customer can also satisfy mandatory documentation requirements for safety components. Limo supplies fibre-coupled


200W diode laser modules for MediCom’s systems. The laser modules feature an intelligent laser processing head and a sensor for non-contact temperature measurement. The systems are used by notable automotive suppliers to weld fuel filter enclosures.


LASER SYSTEMS EUROPE ISSUE 30 • SPRING 2016


Fuel filter enclosures are assembled


using MediCom welding lasers


Peter Bruns, director


applications and technical service at Limo in Dortmund, said: ‘With our solutions, it is even possible to weld automotive components made of glass fibre reinforced plastic, where weld seams need to withstand pulse pressures of up to 65 bar over a temperature range of -40°C to +125°C.’ The new intelligent laser


processing head offers versatile beam geometry and intensity distribution. Because the beam shape is adapted to each individual application, both the quality and productivity of the assembly process can be increased, Limo noted.


@lasersystemsmag | www.lasersystemseurope.com


Tool insert and injection moulded component. Thanks to conformal cooling, the cycle time was reduced by 17 per cent


The uniform cooling channels mean that the


production cycle is now 17 per cent faster than previously. Component deformation is no longer a problem, raising quality and repeatability. After 370,000 cycles, total cost savings amounted to around €20,000. Pavel Strnadek, head of tool maintenance at


Magna, added: ‘There is stiff competition in the European automobile industry. That is why it is very important for us to be able to produce components to the highest quality standards at the lowest price. ‘The issue of injection mould cooling was


something that we have been trying to deal with for a long time. Additive manufacturing has allowed us to make the breakthrough and we are very happy with the results at every level.’


MediCom


EOS and Innomia


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