Thus shaping the future of dies and moulds: With EOS tooling applications
Summary
TLDREOS, a leading manufacturer of laser centering systems, showcases its technology for efficient and cost-effective production from electronic data, suitable for complex and individualized manufacturing needs. The script highlights a partnership with customers to optimize manufacturing solutions, focusing on a children's cup production case study. EOS integrates conformal cooling channels to enhance tooling performance, using its M 270 system with a hybrid design method. The process involves layer-by-layer manufacturing from 3D CAD data, using EOS Maraging Steel S1, a high-performance material for tool making. The result is a 70% increase in productivity, reduced cycle time, and improved product quality, demonstrating EOS's ability to revolutionize the injection molding process.
Takeaways
- 🌟 The OS is a leading manufacturer of laser centering systems, which are crucial for fast, flexible, and cost-effective production from electronic data.
- 🔧 This technology is ideal for industries where complexity and individuality are paramount, or where conventional solutions are insufficient.
- 🚀 The aim is to enhance the productivity of single-cavity injection molds and to elevate the quality of the end product, exemplified by a high-quality plastic children's cup.
- 🤝 In collaboration with customers, the company showcases how to maximize the optimization potential of manufacturing solutions.
- 🔄 By integrating conformal cooling channels, the cooling performance of the tooling insert is significantly improved, enhancing production efficiency.
- 📐 The 3D CAD model is sliced into layers, and the data is transferred to the EOS M 270 system, setting up a hybrid design method that saves time and costs.
- 🏭 The manufacturing process involves a pre-milled tool insert, which is placed in the EOS M 270's process chamber for layer-by-layer construction using a focused laser beam.
- 🛠 EOS Maraging Steel and S1 are chosen materials for their high performance in series tool making, meeting stringent industry requirements.
- ♻️ Unwelded powder from the manufacturing process is removed and can be reused after a simple sieving process, promoting sustainability.
- 🛎️ The finished tool insert undergoes a hardening heat treatment, milling to final dimensions, and polishing to achieve a high-gloss surface finish.
- 📈 The integration of conformal cooling channels results in more efficient cooling, reducing cycle time by up to 40% and minimizing product warpage, leading to higher quality and up to 70% increased productivity.
Q & A
What is the primary function of the laser centering systems manufactured by EOS?
-The laser centering systems by EOS are key for manufacturing fast, flexible, and cost-effective production directly from electronic data.
In which industries is EOS's technology particularly beneficial?
-EOS's technology is suitable for industries where complexity and individuality converge or where conventional solutions don't exist.
What is the main goal of integrating conformal cooling channels in the tooling insert?
-The goal is to increase the productivity of a single cavity injection mold and to improve the quality of the final product.
How does EOS's technology contribute to the manufacturing of a children's cup?
-EOS's technology enables the production of a children's cup made of high-quality plastic by optimizing the manufacturing process.
What is the significance of the hybrid design method mentioned in the script?
-The hybrid design method saves time and costs by using a combination of pre-milled tool inserts and additive manufacturing processes.
What material is used in the EOS M 270 system for the manufacturing of tool inserts?
-EOS M 270 uses a martensitic thermosetting high-performance steel material, known as EOS Maraging Steel and S1, for manufacturing tool inserts.
How does the EOS M 270 system apply material to the building platform?
-The EOS M 270 system uniformly applies the material in powder form to the building platform with a weak odor through a process involving concentrated melting of the powder with a focused laser beam.
What happens to the unwelded powder after the tool insert is completed?
-The unwelded powder is removed from the completed tool insert and can be reused after a simple sieving process.
What is the hardness level of the finished tool insert after the heat treatment process?
-The finished tool insert is hardened to a Rockwell C scale of 254 after an age-hardening heat treatment process.
How does the integration of conformal cooling channels affect the injection molding process?
-The integration of conformal cooling channels enables more efficient cooling of the plastic cups, shortens the cycle time by up to 40%, and reduces warpage in the product, leading to a lower scrap rate and a quality-optimized final product.
What is the potential increase in productivity when using EOS's manufacturing solution in tool making?
-Using EOS's manufacturing solution can lead to a productivity increase of up to 70%, achieving a rapid return on investment.
Outlines
🛠️ Laser Centering Systems for Advanced Manufacturing
The video script introduces the OS company as a leading manufacturer of laser centering systems, which are critical for creating fast, flexible, and cost-effective production processes directly from electronic data. These systems are particularly suitable for industries that require complex and individualized solutions where conventional methods fall short. The primary goal is to enhance the productivity of single-cavity injection molds and to improve the quality of the final product. The script showcases a children's cup made of high-quality plastic, highlighting a partnership with customers to optimize manufacturing solutions. The integration of conformal cooling channels is emphasized as a way to significantly improve the cooling performance of tooling inserts. The process involves slicing a 3D CAD model into layers, transferring data to an EOS M270 system, and using a hybrid design method that saves time and costs. The manufacturing process begins with the placement of a pre-milled insert on a building platform, followed by the application of a martensitic thermosetting high-performance steel powder. The powder is melted layer by layer with a focused laser beam to produce the desired geometry. After the process, the unwelded powder is removed, and the tool insert is hardened and finished to a high-gloss surface.
🔧 Optimizing Injection Molding with Conformal Cooling Channels
The second paragraph of the script focuses on the advantages of integrating conformal cooling channels in the tool insert for injection molding machines. This new design allows for more efficient cooling of plastic cups, reducing cycle time by up to 40%. The optimal temperature distribution also minimizes warpage in the product, leading to a lower scrap rate and ensuring a higher quality final product. The result is a significant increase in productivity, up to 70%, which leads to a rapid return on investment. The script concludes by emphasizing that the EOS manufacturing solution is an ideal way to optimize the conventional injection molding process chain, suggesting that with EOS, the impossible can be achieved.
Mindmap
Keywords
💡Laser Centering Systems
💡Electronic Data
💡Productivity
💡Quality
💡Conformality
💡3D CAD Model
💡Hybrid Design Method
💡EOS M 270
💡Martensite Thermosetting High-Performance Steel
💡Cycle Time
💡Return on Investment (ROI)
Highlights
EOS is a leading manufacturer of laser centering systems, key for fast, flexible, and cost-effective production from electronic data.
This technology is suitable for industries with complex and individualized needs where conventional solutions are inadequate.
The goal is to increase productivity of single cavity injection molds and improve product quality.
Partnering with customers to optimize manufacturing solutions for high-quality plastic products like children's cups.
Integration of conformal cooling channels significantly improves the cooling performance of tooling inserts.
The 3D CAD model is sliced into layers and data transferred to the EOS M 270 system for production.
Hybrid design method with pre-milled tool inserts saves time and costs in the manufacturing process.
EOS M 270 is used for the manufacturing process with EOS Maraging Steel and S1 as the material of choice for tool making.
The manufacturing process involves applying a martensitic thermosetting high-performance steel powder layer by layer.
The building platform lowers after each layer is completed, repeating until the tool insert is fully generated.
Unwelded powder is removed, and the remaining powder is reusable after a sieving process.
The finished tool insert is hardened with an age-hardening heat treatment process to achieve 254 Rockwell C.
The insert is milled to final dimensions and polished to a high-gloss finish before installation.
Conformally cooled tool inserts enable more efficient cooling of plastic parts, reducing cycle time by up to 40%.
Optimal temperature distribution reduces product warpage, lowering scrap rates and ensuring a quality final product.
The result is a productivity increase of up to 70%, leading to a rapid return on investment.
EOS manufacturing solutions optimize the conventional injection molding process chain.
EOS's philosophy is to think the impossible and make it possible.
Transcripts
the OS is the leading manufacturer of
laser centering systems this is the key
technology for a manufacturing fast
flexible and cost-effective production
directly from electronic data this
technology is suitable for all
industries where complexity and
individuality converge or where
conventional solutions don't exist
[Music]
[Music]
the goal is to increase the productivity
of a single cavity injection mold and to
improve the quality of the final product
a children's cup made of high-quality
plastic in partnership with our
customers we'll show you how to take
complete advantage of the optimization
potential of manufacturing solutions
[Music]
through the integration of conformal
cooling channels the cooling performance
of the tooling insert shall be
significantly improved in production the
3d CAD model is sliced into layers and
the data are transferred to the e or
sent system
[Music]
in this example the process is set up
around a pre milled tool insert this
so-called hybrid design method saves
time and costs
the building platform with a pre milled
insert attached is placed in the process
chamber of the eosin m270 the position
is being checked then the powder is
distributed across the building chamber
now the manufacturing process can begin
e OS marriage in steel and s1 is the
material of choice meeting the high
requirements of series tool making this
martensitic thermosetting
high-performance steel and powder form
is uniformly being applied to the
building platform with a weak odor
through concentrated melting of the
powder with a focused laser beam the
desired geometry is produced
automatically layer by layer from 3d CAD
data following each sequence the
building platform is lowered by the
thickness of one layer this step is
repeated until all layers of the tool
insert have been generated and the
production process is completed
[Music]
[Music]
the unwelded powder is then removed from
the completed tool insert the remaining
powder can be reused following a simple
sieving process
the finished tool insert is removed from
the machine and separated from the
platform
it is then hardened with an age
hardening heat treatment process 254
rockwell see
[Music]
the completed insert is milled to its
final dimension and then and polished to
a high-gloss surface finish
following this the core insert is
adapted to the tool and installed in the
injection molding machine
[Music]
now the advantages of a new design
become obvious the integration of
conformal cooling channels in the tool
insert enables more efficient cooling of
the plastic cups and shortens the cycle
time by up to 40%
additionally the optimal temperature
distribution reduces warpage in the
product achieving a lower scrap rate and
ensuring a quality optimized final
product the result is a productivity
increase of up to 70% achieving a rapid
return of investment costs our
conclusion for tool making the EOS a
manufacturing solution
ideally optimizes the conventional
injection molding process chain
you
os think the impossible you can get it
[Music]
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