Design for additive manufacturing of plastic injection tool inserts with maintenance and economic considerations: An automotive study case

Abstract

Additive Manufacturing (AM) allows a simpler and easier production of geometrically complex parts in a single step and with no specific tooling. Hence, it is mostly used for low series or customized products. Accordingly, using AM to produce tools and dies with higher quality could be an economic alternative for high-serial production. This paper presents a proof of the efficiency of the AM in producing tools and dies with higher capability. In this purpose, an industrial study case in the field of plastic injection molding is investigated. Design for Additive Manufacturing (DFAM) is used as the main tool to conceive new cooling channels, so-called conformal cooling systems. The designed cooling systems are numerically simulated using a numerical simulation software designed by Autodesk© specifically for injection molding named Moldflow insight®. Both conventional and conformal designs are compared to prove the efficiency and productivity of the new molds designed for AM and an economic analysis is carried out. Results show that designing for AM allows the conception of unlimited design configurations for conformal cooling channels with highly complex shapes, and regardless of the configuration, an important gain in both cooling time and part deflection is acquired. Furthermore, despite its high cost, tools processed by AM enhance the productivity and accordingly the monetary profit that covers the expenses and makes important economic gains.