Conformal Cooling Design and Manufacturing
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The overall cycle time for an injection moulding process is comprised of 70% cooling time on average. Conformal cooling reduces cycle times and deficiencies during the moulding process.
Conformal Cooling is design strategy implemented when designing injection mould inserts and has been revolutionised in the last 3 to 5 years by 3D Printing (also called Additive Manufacturing(AM)).
Traditional moulding processes now benefit from the 3D printing because with AM moulding inserts can now be designed and manufactured with cooling passageways which follow the shape or profile of the mould core or cavity. The cooling passages are technically name Conformal Cooling Circuits. Injection Mould Cooling Circuits have been implemented in the past but have been bored into the mould inserts in a linear fashion. Linear cooling circuits are just that, linear, and the distance along the cooling circuit and between the mould core or cavity is in turn not consistent and creates cooling dead spots which leads to imperfections in the moulding and cooling process and related imperfections in the finished moulded product.
Deficiencies that can Occur in the Injection Moulding Process
- Flow Lines
- Sink Marks
- Vacuum Voids
- Surface Delamination
- Weld Lines
- Short Shots
- Burn Marks
To determine what effect Conformal Cooling will have on a injection moulded product analyse can be carried out using a combination of people, software, hardware, and manufacturing systems. The analysis demonstrates how the injection moulding process can be modified by implementing conformal cooling channels with end results being the elimination of defects, moulding process deficiencies, and reduced cycle times. Typically, a concise report is provided including what deficiencies and defects will be avoided and also what improvements in cycle time should be experienced.