C A S E S T U D Y C O N F O R M A L C O O L I N G

Linear AMS provides engineering, manufacturing and consulting services to industries where precision and performance are essential. With a successful track record in tooling, molding and

contract manufacturing, Linear’s strengths have always been in engineering and design, short production times and troubleshooting customers’ toughest problems.

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C A S E S T U D Y C O N F O R M A L C O O L I N G

Linear AMS provides engineering, manufacturing and consulting services to industries where precision and performance are essential. With a successful track record in tooling, molding and

contract manufacturing, Linear’s strengths have always been in engineering and design, short production times and troubleshooting customers’ toughest problems.

T H E C H A L L E N G E :

DESIGN AN EFFECTIVE CONFORMAL COOLING SYSTEM TO REDUCE COOLING TIME

In today’s demanding business environment, the ability to produce parts faster and more efficiently is always the top priority for manufacturers.

In this Case Study, Linear used Moldex3D mold simulation software to validate a design to significantly reduce cycle times and improve part quality. The manufacturer needed to produce a higher volume of parts without incurring the costs associated with additional molds and presses.

The cooling process in plastic injection molding traditionally involves longer than optimal cooling times, prolonging the cycle time and ultimately impacting manufacturing volume. Conventionally drilled cooling lines in molding tools have many limitations.

Linear’s Additive Manufacturing (AM)-built molds with Conformal Cooling inserts are superior to conven-tionally machined molds. With their Conformal Cooling technology, the heat/cooling lines in the tool follow the contours of the part. They can be placed an optimal distance from the part surface, allowing the mold to maintain a constant temperature. This technology is ideal for challenging mold geometry, deformed parts and varying wall thicknesses.

To challenge conventional thinking, the experienced and creative design engineers at Linear AMS utilized Moldex3D mold flow simulation software to look for a way to design an effective conformal cooling system that would reduce cooling time and allow the manufacturer to produce more parts without taking more time.

Founded in 2003, Linear AMS is a customer-focused solutions-oriented

partner for plastics mold tooling and production. Today, Linear’s Metal

Additive Manufacturing (AM) experts are integrating manufacturing

innovations and setting new performance standards for making Metal

AM reliable and repeatable throughout the production process.

Founded in 2003, Linear AMS is a customer-focused solutions-oriented

partner for plastics mold tooling and production. Today, Linear’s Metal

Additive Manufacturing (AM) experts are integrating manufacturing

innovations and setting new performance standards for making Metal

AM reliable and repeatable throughout the production process.

Linear AMS12926 Stark RoadLivonia, MI 48150P. 734.422.6060

www.linearams.com

Linear AMS provides engineering, manufacturing and consulting services to industries where

PRODUCING PARTS FASTER AND MORE

EFFICIENTLY THROUGH CONFORMAL COOLINGInnovative Tooling Solutions that Make Better Parts, Faster.

C A S E S T U D Y C O N F O R M A L C O O L I N G

P R O C E S S :

Designing the Optimum Conformal Cooling Layout

Moldex3D eDesign software was used by the design specialists at Linear AMS to analyze the conventional cooling process. (Fig. 1) Significant heat accumulation was discovered in the middle area as well as the shaft. (Fig. 2)

To improve cooling time, Linear’s designers altered the cooling system to conform to the shape of the part. This innovative modification allowed for improved cooling in the middle,the shaft and the outer sides of the part. (Fig. 3)

Using the Moldex3D software to simulate the revised cooling design, Linear’s analysis of the modified cooling channels design showed a much more uniform temperature distribution compared to the original design. (Fig. 4)

As a result, Linear’s designers were able to successfully reduce the cycle time from 65 seconds to just 35 seconds, allowing the customer to produce a higher volume of parts without the need for additional molds or presses.

R E S U L T S :

Substantial Reductions in Cooling Time Result inLower Manufacturing Costs

• Cooling time was reduced by 69%, providing a competitive advantage in the market• The client was able to produce a higher volume of parts without adding additional molds and presses into the process.

Fig. 1

Fig. 3

Fig. 5 - Conformal Cooling reducedcooling cycle by 69% overconventional cooling.

Fig. 6 - Conformal cooling can increase tooloutput while reducing footprint required forcapacity.

Fig. 2

Fig. 4

CONCLUSION: With their advanced design capabilities and experience with Moldex3D

eDesign software, Linear’s AM experts are able to make cooling cycle time reduction

predictions that are consistently accurate, resulting in significant manufacturing savings

for their clients over time.

S E T T I N G N E W M A N U F A C T U R I N G S T A N D A R D SS E T T I N G N E W M A N U F A C T U R I N G S T A N D A R D S

CONFORMAL SAVINGS

COOLING CYCLE

PACKING

FILLING

MISC

REDUCTIONS IN COOLING TIME = LOWER MANUFACTURING COSTSREDUCTIONS IN COOLING TIME = LOWER MANUFACTURING COSTS

HEAD-TO-HEAD COMPARISON:CONVENTIONAL VS. CONFORMAL COOLING

CONFORMALCOOLING

CYCLE30 SECO N D CYC L E SAVINGS

35SECONDS

CONVENTIONALCOOLING

CYCLEC

O O L I N G C Y C L E

65SECONDS

Substantial Reductions in Cooling Time Result inSubstantial Reductions in Cooling Time Result in