Conformal Tooling Briefing

Rapid Tooling: how to accelerate production cycles via conformal cooling using DMLS

3T RPD Ltd can now make your tooling inserts significantly more efficient in the production runs through the use of Direct Metal Laser Sintering (DMLS).

DMLS works by building up the insert in layers, melting powder with a high-power laser in 20 or 40 micron layers. The result is a tooling insert in Maraging Steel for production, which includes conformal cooling channels and requires minimal finishing work due to its excellent resolution and accuracy. The conformal cooling channels, built closely to the contours of the part cavity, can provide you with a substantial competitive edge in bidding for high volume production run tooling due to the reduction in cycle times achievable and potential reduction of distortion of the parts too.

Production insert of an electrical box - building time: core + cavity, 35h

So what are the disadvantages with the DMLS technology? As it happens, there are very few. The biggest challenge is to design them in the most efficient way. However, it is still currently difficult to obtain accurate 3D thermal simulation using commercial simulation packages. Consequently, you need a supplier that has significant expertise in this field to avoid problems. There are also some limitations to the shapes that you can create within the tool insert, but again clever design and experience can overcome this.