ADDITIVE MANUFACTURING ALLOWS COOLING CHANNELS WITHIN MOLD TOOLING INSERTS TO FOLLOW THE FORM OF THE TOOL RATHER THAN BEING STRAIGHT DRILLED HOLES

St. Paul, MN — (August 9, 2019) Transcript from Additive Manufacturing Magazine’s video-Peter Zelinski, Editor-In-Chief.

“One of the most significant impacts of metal additive manufacturing is going to be on plastic part production. I’m referring to conformal cooling the chance to use additive manufacturing to build conforming cooling channels into an injection mold component. More effective cooling potentially means seconds per part shaved from the injection molding cycle, the cycle making a plastic part.

Now seconds for part might not sound like much, but multiply that across millions of parts that might be made through injection molding that might be made using a tool like this and the result could be production so much faster that fewer injection molding presses would be made to achieve the same production in the same amount of time.

One other feature of this machine from Matsuura, it is a hybrid machine. In addition to building additively, it also mills as it goes. It machines the part to completion within the same cycle. The result can be considerable lead for the chance to make this component complete all in one cycle as opposed to different setups for machining, EDM, ETRI.”

Watch the Video HERE.

Matsuura’s LUMEX Technology relies on one-machine, one-process manufacturing of complex molds and parts by fusing metal laser sintering technology with high speed milling technology. The Hybrid technology creates a “finished” part with machined surface finish and accuracy, without inducing the additional variation caused by multiple machine set-ups and part handling.

According to Tom Houle, Director, LUMEX NA, Matsuura’s Hybrid additive/subtractive machining produces highly accurate parts from metal powders that are melted and sintered using a laser while surfaces are precisely milled at high speeds. This technology allows the ability to “grow” a metal component in layers with complex internal features and fine mill those internal features, as the layers are added, to give a perfect surface finish are what makes the LUMEX Series such a distinctive, unique and remarkable production platform and machine tool.

Houle credits that the hybrid technology is a proven solution for moldmakers. In most cases, the proper implementation of the hybrid technology in a mold component will eliminate the need for EDM. This in and of itself is a large time saver in the mold build process. Many components can be completely machined in the hybrid machine, there is an elimination of queue times to get other work completed on a component, typically reducing overall mold build time.

Houle believes the benefit to the owner of the mold is clear: improved cycle times, sometimes as much as 50 percent using conformal cooling, and improved part yields and initial part quality by utilizing the variable porosity capabilities of the powder bed fusion process to assist in the venting of mold gases in the flow front. The Matsuura LUMEX Technology has completely disrupted the part design paradigm. Instead of starting from a block or some other traditional geometric shape, the designer now begins with a blank page to ‘grow’ their designs for lightest weight, sleekest design, and most efficient use of material.

The use of the term, “sintering” is a generic description of the process that most Metal AM machines use. The technology utilized in the Matsuura LUMEX series is more accurately described as Powder Bed Fusion with “selective laser melting.” For the Hybrid technology, this machine configuration provides the most benefits and allows the user to capitalize on the unique features that can be created with the Matsuura LUMEX Hybrid.

The Matsuura LUMEX technology complements the milling process by utilizing Powder Bed Fusion. This technology provides excellent stability and repeat-ability, which allows the machine to know where in the coordinate system the build is taking place and maintain the overall accuracy of the completed part.

The ability to “grow” a metal component in layers with complex internal features and fine mill those internal features, as the layers are added, to give a perfect surface finish are what makes the LUMEX Series such a distinctive, unique and remarkable production platform and machine tool.

Matsuura’s combination of additive and subtractive technologies enables the production of parts and component geometries in a method that has never been possible or imagined. Often referred to as a “one machine, one process” system, the Matsuura LUMEX series permits production of the most complex and challenging parts through total manufacturing by digital engineering using 3-D data. The process produces highly accurate parts from metal powders that are melted and sintered using a laser while surfaces are precisely milled at high speeds. These machines possess both high-speed milling and laser sintering capability.

Matsuura Machinery USA, Inc., located in St. Paul, MN is the U.S. subsidiary of Matsuura Machinery Corporation in Japan. Since 1935, Matsuura has been the forerunner in designing innovative technology and manufacturing solutions to a variety of industries around the globe. Matsuura Machinery USA, Inc. delivers unmatched excellence in 5-axis, vertical, horizontal, linear motor, multi-tasking CNC machine tools and machines with a powder bed metal AM platform with machining capability. Matsuura Machinery USA, Inc. provides the service, applications and technical field support that have always been the Matsuura standard for business. For more information on Matsuura products, contact: [email protected]