1. WTCM - CRIF LBMM Layer Based Mould Manufacturing Comparative study for mould inserts with conformal cooling channels thierry.dormal@crif.be

2. WTCM - CRIF 2 Standard Test Geometry G F C E B D A E H Product size: 125 x 41 x 55 mm Shot volume 22.5 cm 3 Wall thickness 2 mm + living hinge 0.4 mm + thicker parts (5~6 mm) Overall draft of 3° I I SLS prototype

3. WTCM - CRIF 3 Cavity: 1029 cm 3 Core: 481 cm 3 Geometry of the mould inserts with CCC

4. WTCM - CRIF 4 Standard inserts – comparative study Process PrometalEOS DMLS Conc Laser Strato conc Material R10 - S4DM20H20CL50CL201.2311 Cost (€) 2 88012 00023 80048 00026 5006 800 Building time (h) 18 + 48 (furnace)150290850450 ?? Tensile str. 682 MPa400 MPa1100 MPa1200 - 1400650 MPa920 -1730 Hardness 105 HRB65 HRB> 110 HRB110 HRB100 HRB95 HRB 27 HRC-39 HRC37 HRC20 HRC 18 – 51 HRC Comments 1 – 2 mm overdim. 0,3 - 1 mm overdim. Laminated tool Not finished Shotpeening Not finished Limited CCC geometry No supportsSealing Cracks Test inserts (core + cavity) : 190 * 90 * 73 mm and 190 * 90 * 67 mm

5. WTCM - CRIF 5 DMLS inserts (Bronze DM20)

6. WTCM - CRIF 6 - Metallic binder - 240 W CO 2 laser – fiber laser (M270) - Partial melting - Direct manufacturing: no furnace step - Porous bronze or nearly full density steel - Supports required - Speed : 5 – 20  70 cm3/h DMLS: Direct Metal Laser Sintering

7. WTCM - CRIF 7 - No binder - No infiltration - No furnace step - YAG 100 W - Full density steel - Stainless Steel - Ti - Supports required - Layer thickness: 50 µm - Accuracy: 0.1 - 0.2 mm - 250 * 250 * 250 mm - 765 MPa - Speed : 5 cm3/h Selective Laser Melting (MCP, ILT, F&S)

8. WTCM - CRIF 8 - No binder - No infiltration - No furnace step - Full density steel - Supports - Finishing process required - Modular concept (laser marking, laser erosion) - Layer thickness: 20-30 µm - Accuracy: 0.1 mm - Min detail : 1 mm  0.5 mm - Size: 250 * 250 * 170 mm - Stainless steel – Ti - Good results for KUL benchmark - Tensile strength: 1500 MPa - Building speed: 5 cm3/h Concept Laser (D)

9. WTCM - CRIF 9 Some basic redesign required for SLM, Concept Laser,… But also redesign of the CCC & the mother mould…

10. WTCM - CRIF 10 ProMetal Process Step 1. Print – Create metal preform by inkjet printing onto layers of metal powder Step 2. Thermal Processing – Sinter to full density, or sinter and infiltrate

11. WTCM - CRIF 11 3 DP ProMetal with S4 powder Initial conditions –Prometal R10 (CRIF) –Offset: 2 mm Results –Building time: 18 h + 48h (furnace) Box with bronze to infiltrate Feeding blocks Alumina

12. WTCM - CRIF 12 Stratoconception Ideal thermal regulation:  The cooling channel constitute a “cooling sheet” in geometrical conformity with the part external surface.  The distance between cooling sheet and molding shape depends on the zone to cool down and on the chosen cooling system device.

13. WTCM - CRIF 13 Stratoconception - The new mold design Layer examples:  Each layer includes a part of the “cooling sheet” obtained by micromilling together with a remaining of the mold.  The complete mold and desired “cooling sheet” are obtained by assembly of the layers.

14. WTCM - CRIF 14 Standard inserts – comparative study Process PrometalEOS DMLS Conc Laser Strato conc Material R10 - S4DM20H20CL50CL201.2311 Cost (€) 2 88012 00023 80048 00026 5006 800 Building time (h) 18 + 48 (furnace)150290850450 ?? Tensile str. 682 MPa400 MPa1100 MPa1200 - 1400650 MPa920 -1730 Hardness 105 HRB65 HRB> 110 HRB110 HRB100 HRB95 HRB 27 HRC-39 HRC37 HRC20 HRC 18 – 51 HRC Comments 1 – 2 mm overdim. 0,3 - 1 mm overdim. Laminated tool Not finished Shotpeening Not finished Limited CCC geometry No supportsSealing Cracks Test inserts (core + cavity) : 190 * 90 * 73 mm and 190 * 90 * 67 mm

15. WTCM - CRIF 15 Summary For this specific geometry (190 * 90 * 73 mm and 190 * 90 * 67 mm) DMLS DM 20: sealing required (epoxy infiltration). Lifetime? DMLS H20: cracks, long building time (  expensive). MCP SLM and Concept Laser: very long building time (  expensive), cracks Prometal: to be post milled, low cost Stratoconception: Low cost. CCC geometry with limited complexity Viable solutions for the case studies: DMLS bronze DM20: limited to medium series (50.000 parts). Small & medium size inserts. DMLS H20: large series but small size only SLM / Concept Laser /…: large series but very small size only Stratoconception: medium or large size Post milling: always required anyway if tol < 0.05 mm

16. WTCM - CRIF 16 Next meetings….Propositions…. Presentations of LBMM technologies by the manufacturers or the service providers: Concept Laser: JB Ventures (Service provider in Holland) MCP SLM: MCP Germany (Sales manager/ mould maker) Stratoconception: Cirtes (France) EOS DMLS: CRIF - FN Herstal - Quicktools Prometal: CRIF