Additive Manufacturing of Mould Inserts with Mirror-like Surfaces

Francesco Giuseppe Biondani*, Giuliano Bissacco, Peter Torben Tang, Hans Nørgaard Hansen

*Corresponding author for this work

Research output: Contribution to journalConference articleResearchpeer-review

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Abstract

Selective laser melting (SLM) is often applied in the production of steel moulds with high wear resistance and conformal cooling channels for advanced thermal management. The surface finishing of such moulds is crucial, especially if it is intended for the moulding of plastic parts with aesthetic functionality. The surface quality of such metal 3D printed moulds is typically refined by means of subsequent material removal processes, but this is often hindered by residual porosity and inhomogeneity in the metal structure of the 3D-printed part.

In this paper an indirect tooling process chain for production of mould inserts is proposed. The process chain aims at exploiting the good replication capability of electroformed nickel, to copy mirror-like substrates. The bulky part of the insert is produced by means of SLM that shows a considerably higher material deposition rate. The thermal input is controlled throughout the process chain to prevent deleterious grains growth in the nickel layer.

The roughness of the nickel surface is measured after the selective etching of the substrate and compared with the substrate roughness before the nickel deposition, showing good replication of the master surface. The proposed process chain overcomes the problems related to the deposition of thick electroformed coatings by coupling electroforming with higher output additive processes such as SLM - that furthermore allows the introduction of cooling channels in close contact with the mould surface.
Original languageEnglish
JournalProcedia CIRP
Volume68
Pages (from-to)369-374
ISSN2212-8271
DOIs
Publication statusPublished - 2018

Cite this

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title = "Additive Manufacturing of Mould Inserts with Mirror-like Surfaces",
abstract = "Selective laser melting (SLM) is often applied in the production of steel moulds with high wear resistance and conformal cooling channels for advanced thermal management. The surface finishing of such moulds is crucial, especially if it is intended for the moulding of plastic parts with aesthetic functionality. The surface quality of such metal 3D printed moulds is typically refined by means of subsequent material removal processes, but this is often hindered by residual porosity and inhomogeneity in the metal structure of the 3D-printed part.In this paper an indirect tooling process chain for production of mould inserts is proposed. The process chain aims at exploiting the good replication capability of electroformed nickel, to copy mirror-like substrates. The bulky part of the insert is produced by means of SLM that shows a considerably higher material deposition rate. The thermal input is controlled throughout the process chain to prevent deleterious grains growth in the nickel layer.The roughness of the nickel surface is measured after the selective etching of the substrate and compared with the substrate roughness before the nickel deposition, showing good replication of the master surface. The proposed process chain overcomes the problems related to the deposition of thick electroformed coatings by coupling electroforming with higher output additive processes such as SLM - that furthermore allows the introduction of cooling channels in close contact with the mould surface.",
author = "Biondani, {Francesco Giuseppe} and Giuliano Bissacco and Tang, {Peter Torben} and Hansen, {Hans N{\o}rgaard}",
year = "2018",
doi = "10.1016/j.procir.2017.12.097",
language = "English",
volume = "68",
pages = "369--374",
journal = "Procedia CIRP",
issn = "2212-8271",
publisher = "Elsevier",

}

Additive Manufacturing of Mould Inserts with Mirror-like Surfaces. / Biondani, Francesco Giuseppe; Bissacco, Giuliano; Tang, Peter Torben; Hansen, Hans Nørgaard.

In: Procedia CIRP, Vol. 68, 2018, p. 369-374.

Research output: Contribution to journalConference articleResearchpeer-review

TY - GEN

T1 - Additive Manufacturing of Mould Inserts with Mirror-like Surfaces

AU - Biondani, Francesco Giuseppe

AU - Bissacco, Giuliano

AU - Tang, Peter Torben

AU - Hansen, Hans Nørgaard

PY - 2018

Y1 - 2018

N2 - Selective laser melting (SLM) is often applied in the production of steel moulds with high wear resistance and conformal cooling channels for advanced thermal management. The surface finishing of such moulds is crucial, especially if it is intended for the moulding of plastic parts with aesthetic functionality. The surface quality of such metal 3D printed moulds is typically refined by means of subsequent material removal processes, but this is often hindered by residual porosity and inhomogeneity in the metal structure of the 3D-printed part.In this paper an indirect tooling process chain for production of mould inserts is proposed. The process chain aims at exploiting the good replication capability of electroformed nickel, to copy mirror-like substrates. The bulky part of the insert is produced by means of SLM that shows a considerably higher material deposition rate. The thermal input is controlled throughout the process chain to prevent deleterious grains growth in the nickel layer.The roughness of the nickel surface is measured after the selective etching of the substrate and compared with the substrate roughness before the nickel deposition, showing good replication of the master surface. The proposed process chain overcomes the problems related to the deposition of thick electroformed coatings by coupling electroforming with higher output additive processes such as SLM - that furthermore allows the introduction of cooling channels in close contact with the mould surface.

AB - Selective laser melting (SLM) is often applied in the production of steel moulds with high wear resistance and conformal cooling channels for advanced thermal management. The surface finishing of such moulds is crucial, especially if it is intended for the moulding of plastic parts with aesthetic functionality. The surface quality of such metal 3D printed moulds is typically refined by means of subsequent material removal processes, but this is often hindered by residual porosity and inhomogeneity in the metal structure of the 3D-printed part.In this paper an indirect tooling process chain for production of mould inserts is proposed. The process chain aims at exploiting the good replication capability of electroformed nickel, to copy mirror-like substrates. The bulky part of the insert is produced by means of SLM that shows a considerably higher material deposition rate. The thermal input is controlled throughout the process chain to prevent deleterious grains growth in the nickel layer.The roughness of the nickel surface is measured after the selective etching of the substrate and compared with the substrate roughness before the nickel deposition, showing good replication of the master surface. The proposed process chain overcomes the problems related to the deposition of thick electroformed coatings by coupling electroforming with higher output additive processes such as SLM - that furthermore allows the introduction of cooling channels in close contact with the mould surface.

U2 - 10.1016/j.procir.2017.12.097

DO - 10.1016/j.procir.2017.12.097

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EP - 374

JO - Procedia CIRP

JF - Procedia CIRP

SN - 2212-8271

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