Can You 3d Print A Mold Insert With A Flawless Finish?
ฝัง
- เผยแพร่เมื่อ 6 มิ.ย. 2024
- In this video we are attempting to 3D Print a Mold Core Insert with internal conformal cooling chambers. We will then grind the surface to a perfect surface finish using the Studer S31 from United Grinding. Question is. Will there be porosity in the printed H13 steel? 3D printed on the Markforged MetalX… Let’s see if it’s withstands the test.
00:00 Intro
00:27 What is a Mold Insert
01:54 Preparing for 3D Print
02:17 3D Printing on the Markforged MetalX
02:52 3D Mold Insert
03:14 Grinding on the Studer S31
03:26 Setting up Mold Insert into Machine
03:44 Grinding Mold Insert
05:10 Changing Chuck & flipping Mold Insert
05:55 Indicating Mold Insert
06:19 Grinding Montage
07:58 Finished Mold Insert
08:15 Surface Finish Check using Mitutoyo
09:12 Outro
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#Machining #Machinist #Engineering - วิทยาศาสตร์และเทคโนโลยี
As a Toolmaker,this is one of the most impressive things I've ever seen.From the printing to the cylindrical grinding
A company that I worked for did an insert like this about 5 years ago. Had a vendor 3D print it for us, and we did the machining. It had a steeper angel to the coolant channels, but same idea. It works well, and the mold is still running.
Amazing tech and talents. Content never gets old as there is always so much to learn. A big shout out to the post production guys that put these videos together. Much love and gratitude
This was incredible to watch! I love seeing behind the scenes and how advancements in the technology are being used like this. Thank you for sharing this!
Great work Trevor & Chris! Love the technology and that ground finish!👏👏
Yes. Love to see this kind of stuff on 3D printers!!
Actual complex geometries for real industrial applications. Not just making a spanner or a square block
I always wondered what it would take to refine the finish of 3D printed metal parts with a CNC machine and this is one of the most through and satisfying videos on the subject. Outstanding
Liked the vibe on this video, been really enjoying the different focus on the recent videos, not just monster cuts. Will you guys be doing more features on plastics in the future?
Pro-Tip: Hold the marker half if an inch away from the part and blow the end of your marker with the air nozzle. Perfectly dispersed marker every time. I use it more than Dykem
This!! This is the way to do it!!
Super awesome video Trevor and Chris! You guys rock!
Outstanding video! THIS is where North America can shine in the Mold making industry. Innovate methods like this will be the key to re-shore the industry. Looking forward to more Mold Making content.
this blew my mind. what a cool combination of technologies!
I'm a mold maker, this is amazing tech I hope to use this in my career.
I machined a 3d printed small rocket assembly for some grad students at CU Boulder. Those internal cooling channels were filled with powdered metal. It was a laser sintering machine. this is the one time that printing with filament is better than laser sintering.
I really love that I work on plastic injection molds and I can say you take this manufacturing to another level love what you do brothers
In the end, I would like to congratulate Mr. Chris on his new baby and wish him good health
I don't know how y'all aren't over 2m subscribers yet. Probably says a lot about American manufacturing. Great time to be in this business, congrats on holding out and making it through the down time in 08, time to be rewarded :)
I'm a old man, I had no idea they were using metal to 3D print parts with. Great video. Thanks for posting!
Loved the music during the grinding process
Special thanks to the editors for that!
@@christophervillalpando1815 Can we get a name for that track ?
+1
I think it's great how much patience you have shown in grinding the component. From a technology perspective, this is exactly what is needed here - a top team that faces new challenges and presents the entire additive manufacturing process chain - printing - grinding - quality assurance.
From an economic point of view, the H13 could also be processed by binder jetting. This would be even faster and in terms of dimensional accuracy, a better tolerance can certainly be achieved compared to the Markforged, if you now how to sinter your part.
Top presentation and explanation!
Thank you was a very interesting part to grind!
Amazing stuff
Damn, that is cool!
awesome video!
Loving the music, more please 👍
Ha ha, I also enjoyed the music but didn't know if anyone else would notice!
"All my bolts are Titan'd" see what you did there. 😂
very nice
7:52 so beautyfull. All time i think in this 3D print and some CNC
I much prefer powdered metal bed printing for 3D printing metal parts. You get a finished product straight out of the printer, and they usually have a much higher fidelity.
5 ra from a printer ?
H13 from a LPBF printer might be hard to achieve. Binder Jetting could be a good opportunity. ;)
nice!
this is a game changer i think
3D printing steel! Mind blown! When did this tech arrive?
I'd like to see if the thinner wall causes problems over time denting and wear. Also I'm curious how these inserts would hold up to weld and repair. Would the thinner walls cause more sink than we normally see with laser welding.
Badass, I'm still learning on my Dremel 3d45. Baby steps
I’ve heard those are pretty cool little printers!
@trevorgoforth8963 they are, more expensive than newer ones wich probably much better and better upgradeablity, the filament is proprietary but theres ways around it. I purchased it used on offer up for $500 and have been happy with it for the use I give it and the little knowledge I hold.
Current CNC Precision Machining student here. Yall's company has visited us before. Let me work for CNC TITANS!
What maschines can be used to grind the other side that nicely?
Think about the possibilities you could do with a dmg LaserTech..
All I’m able to say is this process is critical to some aerospace components, nice video! … Then the machinists gets to give himself anxiety attacks about making any little mistake on the expensive additive part 😅
With polymer prints, it's very difficult to get fdm prints liquid tight. Does centered metal parts suffer from this? What's a pressure rating on something like that?
What about the cooling channels? how do you make sure they have a good enough surface finish in order to achieve good coolant flow?
How do you make sure the channel inside is completely hollow thru?
😮😮😮 could have used that a few times
My daily business, still impressive
I use permanent marker for grinding. Get a sharpie magnum. It’s a massive sharpie. It makes it so much easier
Smart ass (but honest) question: Since you printed it with a low infill, the cooling channels are not really connected to the wall of the Insert... how good is your thermal conductivity or how much do the channels really do?
Great way of getting it done! At the same time I'm a bit confused on the design side of things. It looks to me like the walls between the cooling channels and the surface that is in contact with the hot plastic are structured like in a part where weight saving is most important. For this part, where the most important aspect is the heat transfer from the plastic to the coolant, I would expect the material in between to be massive in ordner to maximize the heat transfer/ minimize the thermal resistance. Right?
Maybe it should be open inside with fins so we can cool with air like a heatsink.
You will find infill in pretty much any 3D printed part, it isn’t just for weight saving, it means you use less material and it is faster to print. They might have enough heat transfer even with the infill, the bottleneck may be the heat transfer through the plastic not through the infill in which case the infill isn’t really causing any harm. Either way it will still perform better than a machined part without any cooling channels.
@@conorstewart2214 you can't have infill when doing metal powder fdm 3D print like this, since it will cause unpredictable warping of parts during the sintering process. There is software that can account for it, those don't available to markforge machines.
@@QuangNguyen-wb5kd rewatch the video, especially when they show the sliced model, it definitely looks like there is infill there.
I'm not a plastic injection guy,but have experience with aluminum permanent casting. I would wager that that core has to cycle hot and cold for each shot. More mass therefore equates to more time thermal cycling. In aluminum, the entire mold has to be at temperature before the shot can pour consistently. Im guessing Plastic is probably similar.
what kind of hardness could you expect out of 3d printed molds? I would imagine they'd be kinda soft no?
How is the surface 5.8 ?? should´nt it be much more less?
So will the sintering furnace also heat treat the part? Or if you needed a specific heat treat or to draw it back you would need an extra step and a standard heat treating furnace? Charles
The insert comes out of the furnace around 40 HRC. For molds you would want to heat treat it after sintering. Using this process is actually cutting out quite a few steps compared to how you would do it traditionally.
@trevorgoforth8963 thank you, I was assuming that would be necessary. I wasn't sure if the printed materials could even be heat treated or not.
Possible to demonstrate using ASSAB 718 HH (IMPAX HH)
dude how does he grind the tapers?
i just observe something. You remove the part from the 3d printer to the washing station and after that step you put the part in the autoclave with your hand but at the same time the oil of your skin tranfert on the clean part.
1:38 Why dont use gyroid patern? better coling than just coil.
The infill of the 3D print won't transfer heat as well as a solid mass. I could see doing this, but you'd likely want 100% infill with some over extrusion to minimize porosity and maximize thermal mass
Nice, now that i a finally left the mold Business, you create a mold insert 🤦♂
so, question: i saw the printing strategy was a material conservative one, with an inner lattice structure. Doesn't that defeat the conformal cooling, when you have air between the cooling channels and the mold surface?? (aside from conservative mold engineers would deny any structural integrity of that insert, if its not at least 6cm solid metal)
Just what i was thinking, finally someone who gets it...
Reminds me of putting a square in a circle analogy
Why not print it with thicker wall and just lathe the excess?
A completely DAQ for you: It seems that a TON of work is needed to get the "desired"" and absolutely beautiful surface finish on this part. Does this extreme surface finish actually contribute to the part's function of mold extrusion and cooling, or is it mostly for the aesthetics? If it is indeed the latter, is it worth the extra post-processing?
Yeah, it's needed. Molds almost always have to have pretty perfect surface finish. If not the plastic part will have all the roughness of the mold.
If this was an actual insert they would need to polish it to perfect mirror finish - assuming the part is supposed to be smooth, even if the part does not need to be pretty a mirror finish prevents rust and reduces forces needed for removal.
70% improvement? That may be true for this part, but it's not even the best scenario. I saw a showcase once where an injection moulding die had its cooling time reduced from 30 seconds *to just 5 seconds* through redesign with conformal cooling...
This is the way...
why was 100% infill not used? the infill looks like 50% grid pattern. this will reduce the heat transfer significantly as there is an air gap between mold core coolant channel and the core surface make it harder for the heat energy to flow from plastic to the coolant. moreover the way the channel is designed you will end up with uneven temperature distribution leading to warping of the plastic after the part is injected. the deeper part of the mold will have cooler temperature then the less shallow part. This is because the coolant will be in contact with deep part first and its temperature will rise and by the time it get to the shallow part of the mold it will not draw heat efficiently leading to heat distribution over the core.
Its wild that we can 3D print with metal now
@@peepeepoopoo5932 explain why its so easy then?
@@irishwristwatch2487 Bear in mind you’re replying to somebody with the username peepeepoopoo, I wouldn’t expect much in return.
@@PraetexDesignI wouldn’t expect him to return…. At all… 😆😉
@@PraetexDesign oh I know, but there is the off-chance he comes back to make a twat of himself 😂
@@irishwristwatch2487He won’t be back I promise 👍🏼😉
Why was the part ground instead of lathed?
Why is 3D printed in the first place.? This insert can be made without this complicated channel. Obviously, the video is made to show the technology and manufacturing capability.
Stupid question... how does one know what kind of material to run in the grinder vs the lathe .. ?
Lathes can remove material faster, especially if it's softer like aluminum or unhardened tool steel, but aren't going to give as fine a finish. Softer materials can also gum up the wheel on a grinder and give really bad results there. Grinders take longer to remove stock but they can handle much harder materials, like hardened tool steel, and can leave much better finishes.
A lot of times the work process will be to rough it out on the lathe, heat treat, and then bring it to finished size on a grinder.
This must be a sliding core or you forgot about the part ejection process?
Didn't know that Chris was Crafsman
those cooling channels arent that hard to make without 3d printing. just make the core hollow and make a second part with a spiral groove. put them both together and you got the same effect. this is how it was done before 3d printing became an option
Husky 😊 Schoettli 😊
“Give it a little blowie”
I think this insert will not be able to withstand the pressure when the hot material fills the gaps in the mold, because the insert has cavities that have the potential to dent and even break, it should be solid material
I work in IM, and this wall thickness looks really safe, don't forget that this insert NEEDS cooling, normally they would drill a lots of holes and plugged them, this looks way safer and less prone to clogging.
Paying homage to Crafsman?
I didn't get why use a slow grinding wheel instead of a lathe
Surface finish maybe
Surface finish is one reason.
Plus the lathe far more likely to chip the sintered material than a grinding wheel, potentially scrapping the part and making that slow grinding wheel not suddenly seem such a bad idea for a one off part.
Why does it have to be washed? Does it smell when it comes out like when I get sweaty? 😂😊
Why the cooling is not already in the original mold? why you not show the part when its put togehter withe the original part? A lot of work, for what?
Lol, this would piss Slant3D off.
Without injected molded part this episode feels... unfinished.
Love the channel but will you all please machine more parts and less words and pats on the back.
Just remember this is a demo. This is not a legit core for a plastic injection mold. For starters, there is no ejection for the molded part. A high volume mold for this part might be beryllium copper cores with sleeve ejection. No incredibly expensive equipment required. What I dislike about this is some upper management type sees stuff like this and believes that this how it should be done because he saw it on TH-cam. 3d printing will have a place in mold making but this ain’t it.