Case Study of Large Three-Dimensional-Printed Slider with Conformal Cooling for High-Pressure Die Casting

Area of Science:

• Manufacturing Engineering
• Materials Science
• Additive Manufacturing

Background:

• Metal 3D printing offers advantages for high-pressure die casting, particularly with conformal cooling for improved casting quality and efficiency.
• The scalability of 3D printing for large components in serial production, such as engine blocks, remains a key question.

Purpose of the Study:

• To assess the feasibility of using laser powder bed fusion (L-PBF) for manufacturing large conformal cooling components for serial production.
• To evaluate the performance, durability, and cost-effectiveness of 3D-printed components compared to conventional methods.

Main Methods:

• Redesign and manufacturing of a slider component with conformal cooling using L-PBF.
• In-situ monitoring of the tool's temperature field during serial production.
• Comparison of simulation results (SW ProCAST) with real-world performance data.
• Analysis of repair data and production costs for both 3D-printed and conventional tools.

Main Results:

• Successfully manufactured and implemented a large 3D-printed slider (270 × 270 × 200 mm) in serial production.
• Conformal cooling significantly improved tool life and reduced the frequency of repairs.
• Temperature field monitoring confirmed simulation accuracy and demonstrated the benefits of optimized cooling.

Conclusions:

• Metal 3D printing is a viable technology for producing large, complex components for demanding serial production environments like automotive manufacturing.
• The implementation of 3D-printed conformal cooling systems enhances tool performance, reduces maintenance, and offers potential cost savings.