3D-Printed Mold Assembly With Sealed Cooling Channels
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Solution Overview
Problem
Current preproduction molding and molds are expensive and have long build times, limiting the acceleration of the preproduction process and increasing costs, while failing to improve parts production efficiency and utility.
Innovation Solution
The use of additive manufacturing with high-performance plastic filament to create molds via CAD design, 3D printing using FDM, and post-processing such as CNC machining, with strategically designed cooling channels sealed using a high-pressure liquid sealant, allowing for rapid iteration and lower costs compared to traditional metal molding methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional metal molding and molds are used, then production quality and durability are improved, but manufacturing cost and build time increase significantly
Solution Approach 1:
The patent changes the material parameter from traditional metal to high-performance thermoplastic composite materials, and changes the manufacturing process parameter from subtractive (machining) to additive (3D printing) manufacturing. This allows production of durable molds at lower cost with faster build times while maintaining sufficient reliability for preproduction and prototype applications.
Solution Approach 2:
The patent uses composite materials consisting of thermoplastic matrices reinforced with fibers (such as carbon fiber, glass fiber, or aramid fiber). These composite materials provide enhanced mechanical strength, stiffness, and durability comparable to metal molds, while maintaining the advantages of additive manufacturing including lower cost and faster production.
2Reliability
If traditional metal molding and molds are used, then production quality is improved, but build time increases significantly
Solution Approach 1:
The patent changes the manufacturing process from traditional multi-step metal fabrication (design, machining, assembly, heat treatment) to direct additive manufacturing. This parameter change reduces build time from weeks or months to days or hours, while the use of high-performance thermoplastic composite materials ensures the mold quality is sufficient for preproduction and prototype applications.
Solution Approach 2:
The patent incorporates cooling channels, heating elements, and other functional features directly into the mold design during the 3D printing process. This preliminary integration eliminates the need for subsequent machining and assembly operations, significantly reducing build time while maintaining mold quality and functionality.
3Ease of manufacture
If preproduction molding is used to reduce cost, then manufacturing cost decreases, but lead time remains long
Solution Approach 1:
The patent changes both the material parameter (to high-performance thermoplastics) and the manufacturing process parameter (to additive manufacturing). This combination maintains the lower cost advantage of preproduction molding while dramatically reducing lead time from weeks to days or hours, effectively resolving the trade-off between cost and time.
4Ease of manufacture
If additive manufacturing with thermoplastic composite materials is used, then manufacturing cost and build time are reduced, but material performance and durability may be compromised
Solution Approach 1:
The patent uses thermoplastic composite materials with fiber reinforcements (carbon fiber, glass fiber, aramid fiber) that provide enhanced mechanical properties. These composites achieve sufficient strength, stiffness, and durability for preproduction and prototype molding applications, resolving the concern about material performance while maintaining the advantages of additive manufacturing.
Solution Approach 2:
The patent applies different material properties to different regions of the mold as needed. High-strength composite materials are used in areas requiring durability and load-bearing capacity, while other areas may use standard thermoplastics. This local optimization ensures sufficient mold strength where required while maintaining manufacturing efficiency and cost-effectiveness.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in molds that are produced in 1-2 weeks at significantly lower costs than traditional methods, offering high design flexibility, compatibility with various manufacturing processes, and suitability for industrial use, while maintaining high quality and durability.
Implementation Method 1
Molds are 3D printed using FDM (Fused Deposition Modeling) out of thermoplastic materials
Implementation Method 2
a liquid sealant at high pressure is infused and cured to ensure liquid tight cooling channels at elevated pressures
Data Source
AI summary
A mold assembly for use in manufacturing parts includes a first and second mold halves and a mold temperature control system. The first mold half comprises at least a first mold cavity and a first coolant passage. The second mold half comprising at least a second mold cavity and a second coolant passage. The mold temperature control system is in fluid communication with the first and second coolant passages of the first and second mold half. The mold temperature control system comprises a fluid, a means to control the temperature of the fluid, and a pump to circulate the fluid through the mold temperature control system and the first and second coolant passages.