Thus shaping the future of dies and moulds: With EOS tooling applications

EOS 3D Printing

9 Sept 201106:35

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

00:00

🛠️ 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.

05:00

🔧 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

Laser centering systems are critical in the manufacturing process as they ensure precision alignment, which is essential for high-quality production. In the context of the video, these systems are key to the manufacturing of fast, flexible, and cost-effective products directly from electronic data. The technology is highlighted as suitable for industries where complexity and individuality are paramount, suggesting its role in custom or intricate manufacturing processes.

💡Electronic Data

Electronic data refers to information stored in digital form, which can be processed and manipulated by computers. In the video, electronic data is the starting point for the manufacturing process, indicating a reliance on digital design and automation. This underscores the modern, tech-driven approach to production, where physical products are created directly from digital blueprints.

💡Productivity

Productivity in the video is associated with the efficiency and output of a single cavity injection mold. The goal is to increase this productivity, which is a measure of how effectively resources are used to produce goods. The video suggests that by using advanced manufacturing technologies, such as those provided by the OS, productivity can be significantly enhanced, leading to more output with the same or fewer resources.

💡Quality

Quality is a central theme in the video, particularly in relation to the final product. The manufacturing process is aimed at improving the quality of products, such as a children's cup made of high-quality plastic. This implies a focus on precision, durability, and performance, which are critical factors in customer satisfaction and product success.

💡Conformality

Conformality in this context refers to the design of cooling channels in the tooling insert that match the shape of the product being manufactured. This is highlighted as a way to significantly improve the cooling performance of the tooling insert, which is crucial for the efficient production of high-quality parts. The video demonstrates how conformal cooling channels can lead to more efficient cooling of the product, thus improving the manufacturing process.

💡3D CAD Model

A 3D CAD (Computer-Aided Design) model is a digital representation of a three-dimensional object, used extensively in engineering and manufacturing. In the video, the 3D CAD model is sliced into layers, and the data are transferred to the EOS system, which is a step in the additive manufacturing process. This showcases the integration of design and manufacturing, where digital models directly inform the physical creation of products.

💡Hybrid Design Method

The hybrid design method mentioned in the video combines traditional manufacturing techniques with newer, innovative approaches. It involves setting up the process around a pre-milled tool insert, which saves time and costs. This method exemplifies the video's theme of optimizing manufacturing solutions by blending conventional and advanced technologies to achieve better results.

💡EOS M 270

The EOS M 270 is a specific model of a 3D printing system used in the manufacturing process described in the video. It is the machine where the building platform with the pre-milled insert is placed, and the manufacturing process begins. The mention of this machine highlights the role of advanced equipment in achieving the video's goal of fast, flexible, and cost-effective production.

💡Martensite Thermosetting High-Performance Steel

Martensite thermosetting high-performance steel is a material used in the manufacturing process, chosen for its ability to meet the high requirements of series tool making. The video emphasizes the material's properties, such as its strength and durability, which are essential for creating robust tool inserts that can withstand the rigors of the manufacturing process.

💡Cycle Time

Cycle time in the video refers to the time it takes to produce one unit of a product, such as a plastic cup. The integration of conformal cooling channels in the tool insert is said to shorten the cycle time by up to 40%. This reduction in cycle time is a key performance indicator in manufacturing, as it directly impacts productivity and efficiency.

💡Return on Investment (ROI)

Return on Investment (ROI) is a financial metric used to evaluate the efficiency of an investment. In the video, it is mentioned in the context of the productivity increase of up to 70%, which implies a rapid ROI. This suggests that the manufacturing solutions provided by the OS not only improve the production process but also offer a strong financial benefit, which is a key selling point for potential customers.

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.