1. Some molds have internal structures that cannot be cast or machined, so 3D printing is the only option
2. Reduced manufacturing costs
3. Reduced cycle times and shorter lead times through form-following cooling and thermal management
Specific benefits:
1. The internal structure of some molds cannot be cast or machined, so the only option is to use 3D printing technology. When you come across some geometries that are so complex that they cannot be machined by traditional processes, 3D printing can be carried out with ease. Even better, as long as it meets the build range of the printer, the complexity will not generate additional costs. A good example is the ability to print very complex cooling (or heating) lines in plastic injection mold inserts. While traditional CNC processes can produce straight lines and right angles, spiral cooling/heating channels that wrap around are geometries that are difficult to achieve with CNC. Additionally, 3D printing technology can print and process cooling lines for deep, high-finger geometries that can't be cooled or typically require bubblers or cascade fittings. This allows moldmakers to better control mold temperatures, reduce scrap, shorten cycle times, improve dimensional stability and surface finish, and facilitate mold release. This optimized cooling line, often referred to as shape-following cooling, has been shown to reduce cycle times in production by 25% to 75%. In a hyper-competitive market such as plastics molding, such productivity gains are a considerable competitive advantage.
Two, effectively reducing the cost of mold production and manufacturing, some mold components made with mold 3D printing technology can save money. The cost of multiple processes and steps is avoided as components can be printed without the need for programming skills or significant operator time. Cost savings of over 65% have been demonstrated compared to traditional mold manufacturing costs.
Three, effectively reducing lead time, mold components processed using mold 3D printing technology is very speed advantage. Although the time in the design stage is roughly the same, but the finished part of the printing can be completed within a few days, fast or even the same day can be out of the finished product, while the use of traditional processes processing will take weeks or even months. This greatly reduces lead times.
Until now, mold 3D printing has been used in a small number of molds. But as mold 3D printing technology evolves, it will be more widely adopted in mold manufacturing to reduce cycle times, lead times, and costs for prototyping and producing molds.3D printing technology is becoming an essential option for mold makers, just like CNC machining and EDM burn-in.