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Mold cooling circuit optimization results in reductions to both molding process time and costs. Moreover it improves the aesthetic quality of the finished part by both drastically reducing warpage that is related also to the correct cavity filling. In order to achieve this, INglass-HRSFlow is able to provide the customer with, firstly, an analysis of the filling and cooling process and, secondly, the most suitable solution for any required cooling system, including the right positioning.

In order to obtain conformal waterlines, a solution that would be impossible to achieve using traditional machine tool drilling techniques, INglass-HRSFlow is also able to provide the engineering and production of purpose-built inserts using SLM (Selective Laser Melting) technology. SLM inserts are built up in thin layers of metal powder (Maraging 300).

The conformal waterlines are in closer proximity and nearer to the molding surface than those obtained with tooling machines, and thus help to ensure a more uniform mold-temperature distribution.

The SLM process reportedly yields a 99.5% insert density with a hardness ranging from 35 HRc to 54 HRc, as well as mechanical properties that are almost identical to forged steel.

To reduce insert production time and costs, INglass-HRSFlow recommends producing them in hybrid form, where the SLM part of the insert is directly manufactured on a pre-forged base.

SLM inserts with conformal cooling are reported to safeguard against part stress, produce unblemished part surfaces and shorten cycle times.