When manufacturing tooling inserts for HPDC (High Pressure Die Casting), several manufacturing steps such as milling, heat treatment, electro discharge machining and finally surface treatment are involved. By instead manufacturing the insert by SLM (Selective laser melting), the process is expected to be quicker and with less material waste compared to the traditional manufacturing. Examples of other expected advantages is higher product variant flexibility and the possibility of making conform cooling channels, extending the die life. However, the insert is part of a die system involving many components. The insert cannot be designed and manufactured without considering the complete die system. This paper seeks how to integrate the insert design in the die assembly design. This is done via an example component and in cooperation with die manufacturing firms. The result is that the printing is a minor step of the total manufacturing process and that special design considerations needs to be taken for an SLM insert. New die concepts are needed that will minimise the amount of material, reduce the tolerance and surface demand and support the subdivision of the die into several printed parts.
IOS Press, Inc.
6751 Tepper Drive
Clifton, VA 20124
Tel.: +1 703 830 6300
Fax: +1 703 830 2300 email@example.com
(Corporate matters and books only) IOS Press c/o Accucoms US, Inc.
For North America Sales and Customer Service
West Point Commons
Lansdale PA 19446
Tel.: +1 866 855 8967
Fax: +1 215 660 5042 firstname.lastname@example.org