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Additive Manufacturing Takes Conformal Cooling To New Heights

Additive Manufacturing Takes Conformal Cooling To New Heights

Customer challenge

STS has for over 45 years specialized in fabrication moulds for Plastic Injection and Blow Moulds. Their primary customers are from the Automotive Industries. 6 years back, STS adopted the Autodesk Moldflow solution with the vision to improve and optimize on their mould design capabilities. Recent years, many Automotive parts have evolved to be more complex and challenging for their mould fabrication workflow. STS wanted to explore the possibilities to embrace additive manufacturing using 3D Metal Printing Technology to build a complex cooling channel with the objective to reduce cycle time and prolong the tooling's life spend. However, Conformal Cooling is very new to their designers and they needed a verification tool that is capable of helping them to verify the conformal cooling channel that they have designed are effectively extracting heat from the mould.

Project goals

The primary project goal identified was to implement Autodesk Moldflow Insight software to simulate the Conformal Cooling Channel that the team has designed and to ensure the channels are effectively extracting heat. Additionally, the team wanted to achieve an optimized cycle time and prolonged life spend of the mould to save a lot of production costs. Finally, these enhancements would help them to win more business.

Solution

Autodesk Moldflow Insight software has the capability to simulate conformal cooling. STS's designer is now capable of performing simulation on various conformal cooling channel designs, and reviewing the analysis results to determine which design is the most suitable while they can fine tune the process condition to achieve the most optimum results. Autodesk Solution Provider AD&M's technical support team was invited to assist them during the configuration stage and to review the results together while providing a recommendation to improve their channel design.

Business outcome

STS was able to simulate 4 different conformal cooling channel designs using Autodesk Moldflow Insight software within 3 days. They managed to shortlist one of the designs and it took them one day to fine tune the design to achieve their desired cycle time. The cooling design has been sent over to their Metal 3D printing service provider in Singapore for fabrication.

Conclusion

STS was very pleased with the Autodesk Moldflow Insight software's capabilities to be able to assist them in making a decision quickly. Feedback from STS's Sales Director, Mr. Liew is that embracing digital simulation technology like Autodesk Moldflow helps them to increase their competitiveness in the market. Autodesk Moldflow software gives them confidence to try on new technology like Metal 3D printing that would help them to increase their mould efficiency and build stronger relationships and trust with their customers.

Project summary

    Duration & delivery

  • 5
  • 2021-12-27

    Autodesk solutions

  • Moldflow Insight

    Services provided

  • Simulation

    Customer industry

  • Design & Manufacturing
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