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  • Additive Manufacturing Solution

Revolutionizing mold parts with the fusion of
existing technology and additive manufacturing

AM technology of 3D printing has allowed us to produce shapes we may never have imagined before. This new technology gives us more flexibility in the design of molds.
Our innovative technologies including conformal cooling, lattice structures, and molding integration push the limits of what is possible by integrating multiple components into one.

Tooling Innovation
  • Accumulated over 100 years of know-how and experience in mold manufacturing
  • Designing products in a variety of industries such as automotive, motorcycles, and outboard motors
  • Pursues the best metal cutting technologies
Additive Manufacturing
  • Improved cooling performance with the use of conformal cooling
  • Utilizing weight saving techniques through lattice structure and gas venting structure
  • Lead time and cost reduction by integrating molding of multiple parts

AM is the next generation of 3D Metal Manufacturing.
The thought regarding conventional technology

The most common approach to conventional manufacturing includes using machinery such as lathes, milling, grinding, electrical discharge, and high-speed machines. All of these processes remove materials. In other words, it can be said that the thought of conventional manufacturing is a minus technology – subtracting something from an object.

The thought regarding AM technology

AM is short for Additive Manufacturing.
As the word “additive” indicates, AM technology involves adding materials. AM technology manufactures products by slicing 3D modeling data from 0.01mm to 0.1mm thickens in height. The thickness of the component is created by adding layers of material to the cross section on top of each other. In short, AM technology can be thought of as an additive technology that manufactures objects by adding the layers of materials.

  • Additive Manufacturing (AM)

  • Idea of AM processing

Use of AM technology for Molds

Simulate the effects of cooling with the use of flow and thermal analysis software

We will provide you with further innovation by combining the mold-making technology that we have developed over the past 100 years and additive manufacturing. Flow and thermal analysis software can be used to analyze conventional and conformal cooling methods and simulate the expected effects.
We compare the temperatures between cooling effect and cooling uniformity to make an optimal design proposal of each component.
This process can also be applied to the entire mold during the design stage.
These activities at the beginning stage of design along with additive manufacturing allows us to implement ideas with a degree of freedom that transcends preconceived notions of mold making.

Adopting SKD61 Die-steel

We do not settle for less than excellence in manufacturing.
We continue to develop our strategies by adopting SKD61 series die steel, which exceeds the composition and special characteristics of maraging steel. With a commitment to providing 3D additive manufacturing along with the most suitable grades of steel for die-casting molds, we have acquired the facilities and technology needed to carry out the necessary processes from heat treatment, final finishing to quality assurance. (Figure 2)
We are continuously working on improving and pushing the boundaries of innovation.
With our wealth of experience in the field of surface preparation and surface treatments, we can offer you the best possible combinations for your needs.
With this system, we aim to solve our customers QCD (Quality, Cost, Delivery) issues together.

Use of AM technology for molds

Thermal Analysis, AM optimization design and Mold Design

It is possible to optimize cooling efficiency based on the results of thermal analysis using the dedicated software. We are developing a new mold design methods that uses AM from the structural design stage of the mold.
The strength and physical properties of AM products can be analyzed to evaluate and improve their effectiveness.

Additive Manufacturing (powder bed method)

The powder bed method consists of manufacturing by spreading metal powder and melting and solidifying the modeling part with a laser.
Currently, it is mainly used on insert parts.

Facility

GE Additive CONCEPT LASER
- M2 cusing SL 400 W Series 4, 2 machines
◆ Modeling size : 245x245x350mm
(W/D/H)
◆ Maximum molding volume : 22L
　Layer thickness : 20~80μm
　Production speed : 20cm 1/h

material

Daido Steel
- HTC45 High Conductivity Material for molds
(Specializing in SKD61 type of steels)

Heat Treatment

Adjust hardness by tempering insert to remove residual stresses.

Facility

Nabertherm - Chamber furnace N41/H
◆ Maximum temperature:1280℃
◆ Size of the furnace:350x500x250mm, Volume:41L, Weight:260kg
※Mainly used in tempering process

    • Finishing

    We have a total of over 200 machines in our group, including 5-axis CNC, vertical CNC and EDM lathes. Our specialists in mold and part manufacturing select the most suitable processing method for each shape and perform highly efficient and accurate finishing processes.
    We can also coordinate polishing, shot blasting, mirror finish and surface treatment.
    We also have an option for Magneto-Rheological Finishing to improve the roughness of cooling holes.

    Quality Assurance

    We have a variety of inspection machines, including CMM’s and non-contact measuring machines, to meet various warranty requirements.
    We have established a system that allows you to access the material, heat-treat certificates and dimensional inspection by simply scanning a QR codes.
    We can also check results of water flow, flow rate, and pressure leak test.
    After receipt of components, we appreciate any feedback and evaluation so that we may continuously improve.

    Quality Assurance

    Image Analysis System for Quality management

    • ・ Real-time monitoring of melt pool radiation
    • ・ Management automatic coating
    • ・ Monitoring of build envelope
    • ・ Controlling of power and laser condition
    • ・ Measuring powder bed's laser power before and after molding.
    • ・ Analyzing and controlling oxygen concentration in inert gas, management and filtering of gas flow rate.

    Improvement of gas flow

    Due to AM processes using gas laser irradiation for the inset, uniformity of gas flow is important for molding.
    Conventionally the gas flow rate has had disparities due to the shaping position affecting the quality.
    However, gas now flows uniformly after we improved the reproducibility.

    Changes of insert gas flow

    • Convention

    • Present

    Quality Identification

    It is problematic to identify the quality of internal auditing during non-destructive testing.
    In this image of melt-pool construction, we can check every layer like a CT cross section.
    With our high image quality, errors like voids and inclusions in the melt are easily spotted.

    melt-pool image construction system

    Melt Pool 3D visualization

    The images of every layer that are taken by a photodiode camera are calculated as 3D date and visualized.
    This visualization makes it possible for us to do non-destructive testing which enables us to find any melting defects and confirm internal features.

    Changes of insert gas flow

    • data acquisition and correlation

    • 3D Visualizing

      Visualizing 3D melt-pool data