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.

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AMAERO International – History and Milestones

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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

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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

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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.

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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.

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Conformal Cooling Typical Insert Examples

(Hot work tool steel H13, MS1, Hastelloy, SS, INVAR36, Cobalt Chrome, Al

inserts)

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Complex geometry

spiral cooling possible

Close to cavity cooling

Complex cooling channel

Xsection possible

Any effective channel size

Optimal cooling design

from process simulation

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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

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Current standardized conformal cooling tooling supplier example

HTS IC Shot Sleeve Systems (Die Casting) HTS IC Sprue Bush and Plunger Tips (Die

Casting)

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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