Abstract

This chapter studies the potential of additive manufacturing (AM) technologies for injection molds with conformal cooling systems. The analysis is based on a case study intending to compare the performance of conventional machining with two AM technological alternatives: Vacuum Furnace Brazing of metal plates and Direct Metal Laser Sintering. Assuming that the effects of the benefits and drawbacks of the options have different dimensions and time horizons, the comparison is made based on the life cycle perspective of the mold. A Life Cycle Engineering approach is followed, which allows the integrated evaluation of the economic, environmental, and technical performance throughout the mold life. A sensitivity analysis is performed to understand the robustness and is most suitable alternative for different production contexts, taking advantage of the process modeling based on engineering relations. The results show the benefits of AM-based conformal cooling solutions on the mold technical performance, measured by the part quality, together with the economic and environmental advantages for medium to high production volumes.

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