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Conformal Cooling for Tooling Applications
Monash Precinct
25 November 2020
Presented by Sam Tartaglia
AMAERO International – Introduction
Established in 2013 AMAERO is a leading full-service metal Additive Manufacturing(AM) solution provider. Our
organization is founded on core values of Safety, Quality and Delivery.
Our AM solutions begin with a deep understanding of Materials Science, Technology and Repeatability. AMAERO
offers a full-service suite supporting DfAM Engineering, Iterative Prototyping, Serial Component Production and
integrated Machine solutions. We are partnered with leading Universities, Research organizations and Technology
Providers.
Founded in the Monash Precinct and with locations in Melbourne, Adelaide and Los Angeles, we provide an
ecosystem of solutions to some of the world’s largest Commercial and Defense Aerospace Companies.
2
AMAERO International – History and Milestones
3
Jan. ‘12
2013
2017
2015
2016
2018 2019
2012
-AMAERO Eng.
formed
Dec. ‘13
Feb. ‘13
-MCAM formed
Commissioning of EOS
M280 & Trump Trucell
-Concept Laser 1000R
Xline commissioned
Jan-March ‘15
-Expanded local
production facilities
Feb. ‘15
-World’s first 3D
printed Jet Engine
Jan. – Mar. ‘16
-ISO 9001
Accreditation
November ‘16
-Launch of Toulouse
manufacturing facility
Jan. – Dec. ‘17
-Commissioned Concept Laser
Xline 2000r and won various
manufacturing Contracts
Jun. ‘18
-AmPro commissioning
Super metals development
Dec. ‘18
-Commenced planned
expansion and secured
capital
Aug. ‘19
-US Subsidiary formed
LA Office established
LA Plant leased
2020
Jan. – Mar. ‘20
-AS9100 implementation
& Certification
-El Segundo Facility –
Commission
-Production Ready
AMAERO SP500
Receive and Commission
Oct. – Dec. ‘19
--Permits Submitted
-EOS M400 Receive and
Commission
-AMAERO SP 500
-Listed on ASX:3DA
Apr-Jun. ‘20
-Launch of machine sales
-Commence Tooling
project
-First PO for US facility
-First Automotive tooling
PO
World’s first 3D printed jet engine
4
Additive Manufacturing
SLM, DED Technologies
Production
Repair
Alloy Development
Metallurgical Testing
Heat Treatment
Modelling and Simulation
Multi-Material Structures
Laser Joining
Tooling Cores and Inserts
Prototypes
Post-Processing and Finishing
NDT
Design Assistance
Capabilities
R&D and Manufacturing Facilities
North America, El Segundo, CA AS9100 Rev D, ISO9001
Notting Hill, Australia AS9100 Rev D, ISO9001
Adelaide, Australia AS9100 Rev D, ISO9001
5
Current Machine Capability
Amaero has access to some of the world’s most advanced 3D
printing machines. Our machines include:Machine No. Build Volume (x,y,z)
Concept X LINE 1000R 1 630 x 400 x 500 mm (25 x 16 x 20 in)
Concept X LINE 2000R 1 800 x 400 x 500 mm (31.5 x 16 x 20 in)
EOSINT M280 1 250 mm x 250 mm x 325 mm (10 x 10 x 13 in)
EOSINT M290 1 250 mm x 250 mm x 325 mm (10 x 10 x 13 in)
EOS M400 1 400 mm x 400 mm x 400 mm (15.75 x 15.75 x 15.75in)
Trumpf Trulaser 7040 1 160 in.,(406cm), 60 in.(152cm) / 80 in.,30 in.(76cm)
Renishaw AM 400 3 250 mm × 250 mm x 300 mm (10 × 10 × 12 in)
AMAERO SP-500 2 500 mm x 250 mm x 250 mm (20 x 10 x 10 in)
AMAERO SP-100 1 Ø 100 mm x 80 mm
Tooling Applications for Additive Manufacturing (AM)
AMAERO key focus on metal tooling.
Full-service provider – design to supply.
Components for molding tools in plastics, metals and
composites.
Main tool steels currently available as powders include:
Maraging (MS1), Hot work tool steels (H13), stainless
steels, Hastelloy, INVAR36 and Cobalt Chrome.
Proven track record in providing mold inserts in MS1
and H13 for production.
6
Main Drivers
Shorter lead times for prototype parts, tool manufacture and production.
More complex tool designs incorporating features previously not possible,
e.g. close to cavity, matrix structures (lightweight) and venting.
Use of conformal cooling to reduce cycle times and increase productivity.
Reduced thermal fatigue improving mold life.
Product improved quality and less rejects.
Reduced heat checking and soldering.
Optimized product design with less material and lightweight.
7
Conformal Cooling Typical Insert Examples
(Hot work tool steel H13, MS1, Hastelloy, SS, INVAR36, Cobalt Chrome, Al
inserts)
8
Complex geometry
spiral cooling possible
Close to cavity cooling
Complex cooling channel
Xsection possible
Any effective channel size
Optimal cooling design
from process simulation
9
Mold Insert as printed Mold Insert as finished
Mold Insert rear as printed Mold Insert rear as finished
Source: +GF+
Conformal Cooling typical examples
Cylinder Head, combustion
chamber die insert
HPDC sprue post insert
design options
10
Current standardized conformal cooling tooling supplier example
HTS IC Shot Sleeve Systems (Die Casting) HTS IC Sprue Bush and Plunger Tips (Die
Casting)
11
Case studies*: 10, 11 blow molding
Case Studies**: 17-20 die casting
Remaining: Injection molding
CASE STUDY 6
CASE STUDY 17
Source: www.texerdesign.it
Contact us:
www.amaero.com.au
13 Normanby Road
NOTTING HILL VIC 3168
+61 3 9905 9847