Layered Metal Mold Construction With Integrated Cooling and Vacuum
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Solution Overview
Problem
Existing additive manufacturing techniques face challenges in producing large, non-porous metal molds for plastic processing, such as aluminum molds, due to difficulties in temperature control, vacuum application, and void formation, which affect production efficiency and quality.
Innovation Solution
The method involves Cut Layer additive manufacturing, where layers of metal are stacked and machined to form channels for temperature-controlled liquid circulation and vacuum application, using CNC routing to create aligned holes and slots for efficient thermal management and air evacuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If large blocks of material are used to produce aluminum molds through subtractive manufacturing, then the molds can achieve desired geometry, but significant time and material are required to remove excess material
Solution Approach 1:
The mold is divided into multiple thin metal layers that are stacked and bonded together. Each layer is cut from metal sheets to form the cross-sectional geometry of the mold at that height. This segmentation allows the mold to be constructed additively layer-by-layer rather than subtractively from a solid block, dramatically reducing material removal time while maintaining geometric precision.
2Temperature
If metal tubes are attached to the underside of the mold face for temperature control, then thermal management can be achieved, but contact between tubes and mold face is difficult to achieve
Solution Approach 1:
Instead of attaching tubes to the external underside of the mold face (3D external attachment), the temperature control channels are integrated directly into the mold face structure by forming them within the stacked layers themselves. This internal integration eliminates the need for external tube attachment while maintaining thermal contact, as the channels become part of the mold face geometry.
3Temperature
If cast aluminum molds are produced with cooling tubes incorporated inside, then temperature control is improved, but manufacturing inaccuracies and inconsistent distance between lines and mold face occur
Solution Approach 1:
The cooling channels and vacuum holes are formed in each metal layer before the layers are stacked and bonded together. This preliminary formation of channels in individual layers ensures precise positioning and consistent geometry, as the channels are created when the material is still in a manageable sheet form rather than attempting to drill or cast them after assembly. The layers are then stacked with precise alignment to maintain consistent channel positions throughout the mold face.
4Strength
If conventional additive manufacturing uses porous material with catalyzed thermoset liquid infusion, then rigid composite parts are produced, but non-porous metal parts cannot be achieved
Solution Approach 1:
The invention changes the material parameter from porous composite material to solid non-porous metal sheets. Instead of using porous material that requires liquid resin infusion to achieve rigidity, the process uses solid metal layers that inherently provide the required strength and rigidity. This parameter change eliminates the need for porous structures while maintaining or improving mechanical properties, and allows the production of non-porous metal molds.
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 allows for precise control of mold temperature and rapid air evacuation, improving thermal heat transfer and reducing surface markings, thereby enhancing the production efficiency and quality of plastic molds.
Implementation Method 1
circulating temperature-controlled liquid through the tubes
Implementation Method 2
the temperature is appropriately warm, allowing a heat-softened thermoplastic sheet to be forced firmly against the mold face
Implementation Method 3
the sheet can cool sufficiently to retain its shape when removed from the mold
Implementation Method 4
The amount of vacuum (e.g., the vacuum force) is determined by the maximum size of hole that can be used
Data Source
AI summary
A part formed by additive manufacturing includes a plurality of layers including a first layer and a second layer, the first layer and the second layer being stacked along a stacking direction, and a work surface formed on an upper surface of the first layer and an upper surface of the second layer. The part also includes a first through-hole formed in the first layer, a second through-hole formed in the second layer, the second through-hole being at least partially aligned with the first through-hole, and a wall extending from the first through-hole to the work surface.