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Jayesh Modi Managing Director, UltraCool3D [email protected] +61 410 095 160 REDUCING CYCLE TIMES AND IMPROVING PART QUALITY
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Jayesh Modi Managing Director, UltraCool3D
+61 410 095 160
REDUCING CYCLE TIMES
AND IMPROVING PART QUALITY
Confidential, Patent Pending © Ultra Cool 3D 2011
www.ultracool3d.com
• Spending endless hours in trying to control
Warpage?
• Even after all efforts, residual stress in parts
made part unacceptable in field service, can
you afford brand damage?
Warpage,
Long Cycle Times, Tolerances
Confidential, Patent Pending © Ultra Cool 3D 2011
www.ultracool3d.com
Cas
e 1
Simplified
cooling causing
heat build-up
50% cycle time
reduction target
• Very high temperature gradient
• 40 sec cycle time
• High warpage
Development Possibilities –
Automotive siren
Confidential, Patent Pending © Ultra Cool 3D 2011
www.ultracool3d.com
Cas
e 2
Simplified cooling
causing heat
build-up
40% cycle time
reduction target
• Very high temperature gradient
• 50 sec cycle time
• High warpage
Development Possibilities –
Automotive ECU
Confidential, Patent Pending © Ultra Cool 3D 2011
www.ultracool3d.com
Simple IR image
far more effective
than single point
pyrometers used.
Cas
e 3
Development Possibilities –
Automotive Mirror
Confidential, Patent Pending © Ultra Cool 3D 2011
www.ultracool3d.com
Excessive temperature
variation, long cycle time,
warpage.
Cas
e 4
Development Possibilities –
Air Intake Manifold
Confidential, Patent Pending © Ultra Cool 3D 2011
www.ultracool3d.com
Husky Analysis,
12.6 sec. Cycle time
Success Story
Rigid Packaging
Cas
e 5
(Husky Seminar Notes)
Confidential, Patent Pending © Ultra Cool 3D 2011
www.ultracool3d.com
Blocked cooling channel, product quality
issues.
Tool Diagnostic
Rigid Packaging
Cas
e 6
Confidential, Patent Pending © Ultra Cool 3D 2011
www.ultracool3d.com
Ultra Cool 3D’s rigorous design methodology
aims to deliver a
remarkable thermal response.
With proprietary algorithm based on published
research from MIT,
UltraCool3D will help control:
- Warpage
- Weld lines
- Weight
- Cycle time
COST
Quality
Realize those profits
Confidential, Patent Pending © Ultra Cool 3D 2011
www.ultracool3d.com
• Substantially reduce cycle times
• Improve part quality
• Reduce molded-in stresses and warpage
• Control process drift
• Shorten new tool commissioning time
• Sustainability
• Reduced energy & material consumption
• Get ready to minimize your carbon tax
Solution UltraCool3D
Confidential, Patent Pending © Ultra Cool 3D 2011
www.ultracool3d.com
Conformal Cooling
Conventional
cooling
30% Cycle time reduction target.
Project-
Light Switch Bezel
Confidential, Patent Pending © Ultra Cool 3D 2011
www.ultracool3d.com
Project-
“Rib Cage” 3D Cooling
Confidential, Patent Pending © Ultra Cool 3D 2011
www.ultracool3d.com
In addition to part thickness….
Distance- cooling channel
- maximum distance to mold wall.
- minimum distance to mold wall.
- pitch distance.
What causes long cycle times
Confidential, Patent Pending © Ultra Cool 3D 2011
www.ultracool3d.com
54 % extra cycle time
Profit lost !
23o C differential
Warpage !
Why does it matter?
Confidential, Patent Pending © Ultra Cool 3D 2011
www.ultracool3d.com
Process drift (100+ shots to stabilise)
Poor Quality !
23o C
differential-
Warpage
Reversal from
-7 o C to + 23
o C
Un-stable tool
-7 o C
+ 23o C
Why does it matter?
Confidential, Patent Pending © Ultra Cool 3D 2011
www.ultracool3d.com
o Based on algorithm developed at MIT.
o Design for six different criteria- uniform cooling of
part, part eject temperatures, tool strength,
coolant temp., pressure drop.
o This ensures- shortest cycle times with uniform
cooling of parts ensuring best possible
crystallisation, minimal residual stress and
warpage.
o We can help- gap analysis, tooling specification,
design review, tooling manufacture.
Proprietary Software
Confidential, Patent Pending © Ultra Cool 3D 2011
www.ultracool3d.com
Proprietary Software
….. at your service
Confidential, Patent Pending © Ultra Cool 3D 2011
www.ultracool3d.com
• Our technology is developed in Australia and
analysis carried out at CSIRO and Dept. of
Defense facilities by use of advanced scanning
electron microscopes.
Quality Built-in
Confidential, Patent Pending © Ultra Cool 3D 2011
www.ultracool3d.com
At UltraCool3D we are dedicated to bringing
innovative technological solutions to plastics
moulding industry in a manner that will set new
standards of quality and service. We, in our humble
way, will help reduce carbon footprint that our
industry leaves behind. This will lead to more profit
for our customers and have lasting impact on our
planet.
Mission Statement
Jayesh Modi Managing Director Ultra Cool 3D
Confidential, Patent Pending © Ultra Cool 3D 2011
www.ultracool3d.com
Confidentiality Note: Intellectual property protection is sought for various stages of our products, they are protected under
various patents in various stages of application. No part of this presentation or technologies described herein may be copied,
reproduced without express written permission of its proprietors.
Good cooling is not optional…
Jayesh Modi Managing Director Ultra Cool 3D
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