MR30Manufacturing Cell System for eV-LINE OPM molds
apan made products
OPM SeriesLinear Motor Drive Precision Metal 3D Printer
Plus
http://ww
w.sodick.co.jp
ew ERA of the Plastic Molding Revolution
The revolutionary performance of Sodick’s OPM Series of precision
metal 3D printers enables manufacturing of molds (OPM molds)
with built-in three-dimensional cooling channels, fundamentally
changing how molds for plastic products are created.
The OPM Series lineup has been expanded by adding model OPM350L to the
previously available OPM250L model. OPM350L supports larger milling sizes,
and has been designed for faster milling. It has a new parallel mode function,
http://www.sodick.co.jp/product/tool/metal_3d_printer/catalogue/opm350l.html
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of the Plastic Molding Revolutionextended continuous operation function, in-process compensation function, and CNC unit. The OPM Series is creating a
new era in the manufacture of molds for plastic products. Using the OPM Series with the new MR30 manufacturing cell
system for eV-LINE OPM molds enables a comprehensive range of outstanding labor-saving benefits. These benefits include
maximizing the capabilities of molds with built-in three-dimensional cooling channels, improving productivity for molded
products designed for small-lot/high-variety production molding, shortening lead times, and greatly reducing costs.
Reaffirming our founders’ commitment to "Creating What We Cannot Find in the World," the Sodick Group is providing the
latest all-in-one solutions by drawing on proprietary elemental technologies for all production processes.
OPM Series MR30Linear Motor Drive Precision Metal 3D Printer Manufacturing Cell System for eV-LINE OPM Molds
Plus
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Series MR30
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http://www.sodick.co.jp/product/tool/metal_3d_printer/catalogue/opm350l.html
T he OPM Series models are fully automated metal 3D printers that attain a melting ratio of
99.9%. Metallic powder is spread uniformly (re-coating process), melted/solidified by a series
of ten laser emissions, and then subjected to a precision cutting process with high-speed
milling. These operations are repeated to create a 3D printed (layered) workpiece. The laser
oscillator that the OPM Series models use to melt/solidify the metallic powder is a fiber laser with a 500 W
output. The main spindle has a 45,000 rpm spindle that synergizes with Sodick’s original linear motor to
provide high-speed, high-precision metal 3D printing. An automatic tool changer (ATC) and automatic
tool length measuring device are installed to allow continuous automated operation over a long period
of time.
High Speed Metal 3D Printingigh Quality and
7 hr 58 min
7 hr 58 min
Milling speed improvement ◎Parallel mode 2.5 times faster
Cutting speed improvement
◎Less frequent shifting◎In-process compensation
reduces cutting allowance1.5 times faster
0 10 20 30 40 50 60 70 80(Time)
7 hr 58 min 39 hr 14 min
7 hr 58 min 44 hr 35 min
19 hr 53 min 44 hr 35 min
19 hr 53 min 59 hr 56 min
41% reduction
34% reduction
19% reduction
Milling time (per workpiece) Cutting time (per workpiece) *Total milling time consists of the milling time and cutting time, and does not include re-coating or tool replacement time.
Total milling time: 47 hr 12 min ▼Total milling time: 47 hr 12 min ▼
Total milling time: 52 hr 33 min ▼Total milling time: 52 hr 33 min ▼
Total milling time: 64 hr 28 min ▼Total milling time: 64 hr 28 min ▼
Total milling time: 79 hr 49 min ▼Total milling time: 79 hr 49 min ▼Quality
Quality
3 workpieces in parallel
3 workpieces in parallel
New shifting process
In-process compensation
Ten-layer shifting process
New shifting process
New shifting process
Ink tank mold coreWorkpiece Three workpieces in parallel × 2 Enlargement of one workpiece
Overall speed: 1.7 times faster
Larger Milling Size
Melting Ratio99.9%
Milling Speed Improvement
OPM350L has maximum milling dimensions of 350 × 350 × 350 mm (W × D × H), and
a maximum loading weight of 300 kg. It can print large workpieces with 2.7 times
greater volume and 3 times greater weight than OPM250L. A retractable footboard
and large aperture are provided as standard features, enabling the same ease of
operation as OPM250L.
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High Speed Metal 3D Printing
Parallel ModeFunction
Continuous Automated Operation for Extended Periods
In-processCompensation
MRS unit (option, shown on right)
The OPM Series comes with a parallel mode function,
enabling simultaneous milling of multiple locations
by controlling a single laser at high speed. A major
improvement in fume collection capability also
enables high-speed milling while maintaining high
quality. Cavities and cores milled in the parallel
mode can be created with built-in three-dimensional
cooling channels, effective for high-cycle molding.
Sodick has developed an optional MRS (Material
Recovery System) unit to enable fully-automated
metal 3D milling of larger workpieces. Excess material
ejected during the re-coating process is automatically
suctioned up and separated into cutting chips and
powder. Screened material powder is automatically
transferred to the machine, so the material powder
is circulated endlessly and thus making long-term
continuous automated operation possible.
The newly-developed in-process compensation
function periodically measures and compensates the
relative positions of the laser axis and milling axis while
milling. It minimizes the cutting allowance, and reduces
the milling time and cutting time. It also optimizes the
amount of metallic powder used for milling, effective
for saving energy and enabling greener manufacturing
and longer maintenance cycles.
No cutting remnants
OPM350LLinear Motor Drive Precision Metal 3D Printer
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http://www.sodick.co.jp/product/tool/metal_3d_printer/catalogue/opm350l.html
Sodick’s manufacturing cell system for eV-LINE OPM molds was developed to maximize the
performance of molds (OPM molds) with built-in three-dimensional cooling channels created
by OPM Series precision metal 3D printers. The OPM mold is incorporated into a cassette,
greatly reducing mold replacement time. The system also includes all the functions needed for
molding, creating an equipment environment made up of compact cell units.
All-in-one Structure
Two Temperature Control Circuits
Sodick’s MR30 manufacturing cell system has an all-in-one structure
consisting of an eV-LINE injection molding unit combined with all the
peripheral equipment needed for injection molding. It has a compact
design and low height, and saves space and energy. After the resin
pellets (raw material) have been supplied to the tank, all processes (resin
preheating, mold temperature control, injection molding, and product
removal) can be done fully automatically. All the peripheral equipment
settings can be made from the MR30 operation panel, greatly improving
work efficiency.
MR30 comes with two temperature control circuits as a
standard feature. They enable maximum use of the local
cooling circuits created by the three-dimensional cooling
channels built into OPM molds, minimizing cooling time. They
are effective for high-speed injection molding of ultra-thin
products or precision molding of miniature products.
Auto selector(option)
Dryer silo
Drying filter
Granulator
Temperature controllers (2)
Two-stage drying conveyor (option)
Injection/Plasticizing unit
Temperature control circuit (1)
Temperature control circuit (2)
Flow of resin
Production in Great Varietieshe Production Cell System for Small-volume
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Cassette MoldThe cassette mold can be used to support miniaturized/precision
injection molding for small-lot/high-variety production. Inserting the
OPM mold into the cassette mold is the only setup work needed, enabling
optimized waste-free production matched to the production schedule.
MR30Manufacturing Cell System for eV-LINE OPM Molds
Cassette mold
Cassette mold replacement (illustrative example)
Cassette mold (fixed side)
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1 Base mold
2 Cassette
3 Cassette core
4 Cassette cavit y
5 Molding machine noz zle
6 Valve gate
Production in Great Varietieshe Production Cell System for Small-volume
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OPM Series MR30Plus
Example OPM mold with built-in three-dimensional cooling channel: Waterproof connector mold
Waterproof connector flow analysis
The divided components of conventional molds can now be produced as one-piece units. Cooling channel positioning can also be optimized in ways not possible with conventional equipment. These benefits optimize the molten resin material flow, while reducing cooling time and improving stability during mold release.
Production time: 109 hr 40 min* Milling time: 59 hr 10 min Cutting time: 50 hr 30 min Size: 68 × 86 × 53 mm
Production time: 138 hr 53 min* Milling time: 67 hr 49 min Cutting time: 71 hr 4 min Size: 68 × 86 × 45 mm
Production time: 51 hr 35 min* Milling time: 11 hr 33 min Cutting time: 40 hr 2 min Size: 20.76 × 9.58 × 77.66 mm*Production time for 2 workpieces.
*Production time for OPM production only. *Production time for OPM production only.
Production time: 54 hr 29 min* Milling time: 11 hr 49 min Cutting time: 42 hr 40 min Size: 25.00 × 44.51 × 43.56 mm
Fixed side (bottom mold)
Movable side (top mold)
A
A
B
D
D
E
EB
15% 40%
80%
20%
60% 100%
Precedent
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OPM mold component drawing
Major reductions in mold production lead time and molding cycle time
*Production time including post-processing
Conventional mold component drawing
Precedent
Reduces mold production lead time and total cost.
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Mold productiontime
Molding coolingtime
Number ofmold components
Moldingcycletime
Conventional mold
OPM mold Core196.75 hr
Core363.5 hr
Cavity281.5 hr
Cavity215.25 hr
18.0 → 7.5 (seconds)
Conventional mold
Required cooling time (seconds)OPM mold
25.5 → 15.0 (seconds)
Conventional mold
Molding cycle time (seconds)OPM mold
18 seconds
7.5 seconds
25.5 seconds
15.0 seconds
Conventional mold
OPM mold Core196.75 hr
Core363.5 hr
Cavity281.5 hr
Cavity215.25 hr
18.0 → 7.5 (seconds)
Conventional mold
Required cooling time (seconds)OPM mold
25.5 → 15.0 (seconds)
Conventional mold
Molding cycle time (seconds)OPM mold
18 seconds
7.5 seconds
25.5 seconds
15.0 seconds
Conventional mold
OPM mold Core196.75 hr
Core363.5 hr
Cavity281.5 hr
Cavity215.25 hr
18.0 → 7.5 (seconds)
Conventional mold
Required cooling time (seconds)OPM mold
25.5 → 15.0 (seconds)
Conventional mold
Molding cycle time (seconds)OPM mold
18 seconds
7.5 seconds
25.5 seconds
15.0 seconds
Major reduction in lead time
Number of mold components: Reduced from 30 to 9A one-piece mold can be produced instead of a divided mold.
Three-dimensional cooling channel placement not possible with conventional equipment enables stable mold cavity filling, and a major reduction in the cooling time needed before product ejection.
MR30 comes with two temperature control circuits as a standard feature. The optimum local temperature control made possible by these two sets of die temperature control linesenables high-quality high-cycle molding under ideal conditions.
OPM mold with built-in three-dimensional cooling channel Two temperature control circuits enable high-cycle molding
Part No. Quantity Time*
111 1 47.50
112 2 184.00
113 1 31.00
114 1 26.75
115 1 6.25
116 1 5.75
117 1 12.00
118 1 43.50
119 1 6.75
Core total 10 363.50
Part No. Quantity Time*
101 1 119.25
102 2 73.50
103 1 4.00
Core total 4 196.75
Part No. Quantity Time*
521 2 42.50
522 1 106.00
523 1 8.00
524 2 5.25
525 1 8.75
526 1 8.25
527 1 8.00
528 2 6.25
529 2 6.75
530 2 4.75
531 2 5.00
532 1 4.25
533 2 1.50
Cavity total 20 215.25
Part No. Quantity Time*
501 1 161.00
502 1 112.50
503 2 6.50
504 1 1.50
Cavity total 5 281.50
*Production time including post-processing
58% reduction 41% reduction
18% reduction 70% reductionfewer components
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Dimensions
(With optional MRS unit)
Layout
OPM350L Specifications
Max. object size (Width) × (Depth) × (Height) 350 × 350 × 350 mmX-axis travel 360 mmY-axis travel 360 mmU-axis travel 344 mm
Machining tank internal dimensions (Width) x (Depth)
390 × 390 mm
Spindle Z-axis travel 100 mmMax. workpiece loading weight 300 kg
Nitrogen supply capacity 90 NL/minMachine tool dimensions (With optional MRS unit)
2020 × 2485 × 2575 mm
Machine tool weight (excluding peripheral devices) 5800 kg
OPM ULTRA1 (Maraging Steel)OPM SUPER STAR (SUS420J2)
OPM Stainless 316OPM Stainless 630
Machine SpecificationsLaser type Yb fiber laser
Laser wavelength 1070 nmMax. laser output 500 W (1000 W specification optional)
Laser scanning Galvano method
Laser
Options
Metal Powder
Max. spindle rotation speed 6000 to 45000 min-1
Max. spindle torque 0.8 NmATC tool holders 20
Tool holder systemDual-contact shrink fir holder
HSK-E25
Spindle / Automatic Tool Changer
Control axes 6 axes (X, Y, Z, U, B, Spindle)Simultaneous control axes Max. 4 axesMinimum input command 0.1 μm
Minimum drive unit 0.031 μm
LN4RP NC Unit
*Metallic powder used with OPM350L. For details, contact the sales department.
* Only Sodick-specified metallic powder materials can be used.* Some metallic powder materials require the use of a Sodick-recommended base plate.* Use of the OPM Ultra 1 or OPM Stainless 316 metallic powder materials requires a work environment conforming to health and safety laws (in Japan, the Ordinance on Prevention of Hazards Due to Specified Chemical
Substances of the Safety and Health Law).
• MRS unit • 3-light signal tower • External transformer• 100 VAC outlet • Air dryer (primary side) • Air tank • Material-restricting bellows (rectangular type) • 3-phase input cable • Shrink fitting device (Heat Robo) • Base master• Point master • Set of pin cushion parts • Power sifter (unneeded when using MRS unit) • Sifter (unneeded when using MRS unit)
• Sifter tray lid set (unneeded when using MRS unit) • Laser eye protection• Filter replacement dust mask• Filter replacement dust mask filters • Tool cutter• Demagnetizer• Magnetic flux density meter• Vertical probe (for magnetic flux density meter)• Industrial vacuum cleaner (for metallic powder; unneeded when using MRS unit)
• Silent cleaner (for fume cleaning)• High-power cleaner (for floor cleaning)• Initial processing tool set• Laser inspection
• USB memory• Large container (for fume collector cleaning)• Fume collector electrode (spare)• Activated carbon (for replacement)• Sintered metallic element (spare)• Protective synthetic quartz glass (spare)• Slide seal A (spare)• Blade acute (spare)• Blade acute (ceramic)• Fume collector activated carbon catalyst• Three-in-one multi dry filter (standard on overseas models)
• OPM Series Dedicated CAM OS-FLASH
Unit: mm
29202020
450
2575
2125
2195
1880
800
1650
2485
1295
150
600
4530
2340
495
800
780
300
1055
345
545
200
1250
205
-122
145
25
230 670
10502340145
3780
-540
6002001070840100
Cooler Assembly
Input Power Supply3-Phase AC200/220VH=1020 mm
Nitrogen GasGenerator (4NTE-3.7S)
390
Vacuum CleanerJX-3030SK (200V)
Fume Collector (FM-3DPS)
-370
5607102302020300
40
Air inFrom 0.7MPcH=1285 mm
Machine Power Supply
3820MRS-Unit
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Dimensions
Mold mounting drawings
Layout
MR30 Specifications
Maximum clamping force 294 kNTie-bar interval 360 × 360 mm
Daylight (mold thickness + stroke) 625 mmMold thickness 455 mmEjector stroke 50 mm
Screw diameter 25 mmPlunger diameter 22 mm
Maximum injection pressure 180 MPaTheoretical injection volume 27 cm3
Maximum injection speed 150 mm/sPlasticizing capacity 15 kg/hr
Machine dimensions (L × W × H)
2653 × 1462 × 2250 mm
Machine weight 2000 kg
Mold Clamp Plasticizing/Injection Unit Machine Dimensions / Weight
Dehumidifyingdryer
Autoselector(Option)
Mold temperature controller(2 System, Water)
Runner shooter(Option)
Molded part removal robot
Mounting layout drawing
850
540
2000
998
1258
(Par
ting
surf
ace)
(Noz
zle
heig
ht)
1095
1381
250
2250
(407)40590
2500
2653
(652)
View AGranulator
Conveyer(Upper & Lower, Option)
A
Material tank(Option)
2095
63
95
95
9577
0 385
385
310
1225 80
(468
.7)
1461
.6(1
87.9
)
(211
8.2)
71.6
1300
90
900
400
110
110
370
160
183
320
650
650
340
174.
532
0
494.
5
2- 16 H8 ReamerDepth 20
2- 12 ReamerDepth 16 6-M12 Tap Depth 30
Operation side
Fixed platen
370
110
500
500
110
350
340
6-M12 Tap Depth 30
360
360
Operation side
Movable platen
525
519
05
625
192
170
40
50
70
125
85
85 118
59.3
58.74-M12 Tap Depth 18
Upper Mold thickness
Max. Mold open stroke
Open Daylight
Base Mold
Lower Mold thickness
Insulation board thickness for Lower Mold Unit stroke
Ejector stroke Eject start positionCassette Mold
Resin feedBolt hole for hopper
Insulation board thickness for Upper Mold
Operation side
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Printed in Japan
3-12-1, Nakamachidai, Tsuzuki-ku, Yokohama, Kanagawa224-8522 JapanTEL: 81-45-942-3111 FAX: 81-45-943-7880
●�The export of Sodick's products and its related technologies (including software applications) is regulated under Japan's Foreign Exchange and Foreign Trade Control Law. In addition, because some of these products may be subject to re-export controls under the Export Administration Regulations (EAR) of the United States; please contact Sodick before offering or exporting these products overseas.
●This catalogue contains a photographic image that has been generated from 3DCG.●Options may be included in the photos of this catalog.●��Due to ongoing research, specifications are subject to change without prior notice.●The contents of this catalog is current as of July, 2017.
http://www.sodick.jp
S2020801.2017.07<02>
http://ww
w.sodick.co.jp
OPM
Series MR30
apan made products