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This review paper aims to provide an overview of applications of direct rapid manufacturing assisted mold with conformal cooling channels (CCCs) and shows the potential of this technique in different manufacturing processes.

Key publications from the past two decades have been reviewed.

This study concludes that direct rapid manufacturing technique plays a dominant role in the manufacturing of mold with complicated CCC structure which helps to improve the quality of final part and productivity. The outcome based on literature review and case study strongly suggested that in the near future direct rapid manufacturing method might become standard procedure in various manufacturing processes for fabrication of complex CCCs in the mold.

Advanced techniques such as computer-aided design, computer-aided engineering simulation and direct rapid manufacturing made it possible to easily fabricate the effective CCC in the mold in various manufacturing processes.

This paper is beneficial to study the direct rapid manufacturing technique for development of the mold with CCC and its applications in different manufacturing processes.

This paper details the development of a rapid tooling manufacturing route for the gravity and high‐pressure die‐casting industries, resulting from an EPSRC funded collaborative research project between the Universities of Warwick, Loughborough and DeMontfort, with industrial support from, amongst others, MG Rover, TRW Automotive, Sulzer Metco UK Ltd and Kemlows Diecasting Products Ltd. The developed process offers the rapid generation of mould tools from laser‐cut laminated sheets of H13 steel, bolted or brazed together and finish machined. The paper discusses the down‐selection of materials, bonding methods and machining methods, the effect of conformal cooling channels on process efficiency, and the evaluation of a number of test tools developed for the industrial partners. The paper also demonstrates the cost and time advantages (up to 50 and 54 per cent, respectively) of the tooling route compared to traditional fabrication methods.

The purpose of this paper is to present a technique of fabricating profiled conformal cooling channels (PCCC) in an aluminium filled epoxy mould using rapid prototyping (RP) and rapid tooling (RT) techniques and to compare the cooling times for the moulds with circular and profiled channels experimentally. The cooling channels in injection mould tools have a circular cross section. In a PCCC, the cross sectional shape is so designed that the flat face surface of the channel facing the cavity follows the profile of the cavity. These types of channels can be manufactured through RP and RT techniques.

A part to be moulded was designed and modelled. Two moulds were then designed with the part cavity, one having a circular channel and the second with a profiled channel, both having the same cross sectional area for coolant flow. The channel patterns were designed with supports according to their position regarding height and distance from the cavity as designed earlier. Both channels have the same distance from the cavity wall. RP patterns were produced for both channels and part using the Thermojet 3D printer. The cooling channel and the moulded part patterns were then assembled as designed in the moulds. Moulding frames were fabricated with aluminium plates and the pattern was placed in the frames. Epoxy was poured on the pattern and then cured. The moulded part and the channel patterns embedded inside epoxy were melted out during the final curing cycle, leaving behind the circular‐ and profiled‐cooling channels in the moulds. For the cooling time measurement, injection moulding was done with moulds with circular and profiled channels. Moulded part temperature will be recorded by embedding thermocouples within the mould cavities.

A technique for the manufacture of cooling channels of different profiles in epoxy moulds was presented. Experimental analysis for temperature measurement for the moulded part with injection moulding process showed that PCCC mould has less cooling time then mould with circular channels.

The technique presented is based on the metal‐filled epoxy materials used in RT and was obtained using a specific test part. Epoxy tooling can be a useful alternative of metallic mould to produce injection mould tools. A limitation for the epoxy moulds is that they have a limited life as compared with metallic moulds.

This is a new technique of manufacturing moulds with cooling channels using RP/RT techniques. Moulds with different channel cross sections can be manufactured using this technique.

Additive manufacture (AM) such as selective laser melting (SLM) provides significant geometric design freedom in comparison with traditional manufacturing methods. Such freedom enables the construction of injection moulding tools with conformal cooling channels that optimize heat transfer while incorporating efficient internal lattice structures that can ground loads and provide thermal insulation. Despite the opportunities enabled by AM, there remain a number of design and processing uncertainties associated with the application of SLM to injection mould tool manufacture, in particular from H13/DIN 1.2344 steel as commonly used in injection moulds. This paper aims to address several associated uncertainties.

A number of physical and numerical experimental studies are conducted to quantify SLM-manufactured H13 material properties, part manufacturability and part characteristics.

Findings are presented which quantify the effect of SLM processing parameters on the density of H13 steel components; the manufacturability of standard and self-supporting conformal cooling channels, as well as structural lattices in H13; the surface roughness of SLM-manufactured cooling channels; the effect of cooling channel layout on the associated stress concentration factor and cooling uniformity; and the structural and thermal insulating properties of a number of structural lattices.

The contributions of this work with regards to SLM manufacture of H13 of injection mould tooling can be applied in the design of conformal cooling channels and lattice structures for increased thermal performance.

The purpose of this paper is to report on the use of a combination of indirect selective laser sintering (SLS) and machining processes to create injection mould tools, an approach designed to offer the capability to create conformal cooling channels in the core/cavity inserts together with the levels of surface finish and accuracy required to meet typical injection mould tool specifications.

The research has been pursued through three industrial case studies. In each study, existing injection mold inserts have been redesigned to give a conformally cooled tool. These have then been manufactured using indirect SLS, high‐speed machining, electro‐discharge machining and polishing. The inserts have been evaluated in industrial trials to assess their performance in terms of cycle time, energy usage, durability and quality. The insights gained from the three case studies have then been developed into a series of design rules, which may be applied in the development of tooling for new applications.

The results show that significant productivity improvements and energy use reductions in injection moulding are possible through the implementation of conformal cooling, and that the material has sufficient wear resistance to be used in production applications. However, it is recommended that modelling is always used to understand the impact of conformal cooling channels, and manufacture is carefully planned to ensure that the required internal geometry is created.

The paper presents new results on the impact of conformal cooling on the productivity and energy efficiency of injection moulding, and on the durability of the indirect SLS material in injection moulding applications. A novel “cut‐out volume” technique for powder clearing is also presented, along with a set of design rules to support further application of the work.

The purpose of this study is to compare the overall performance of the injection moulding process by using metallic inserts produced by both conventional technologies and selective laser melting (SLM).

A systematic methodology is proposed for prior evaluation of the effectiveness of conformal cooling channels to reduce cycle time and/or to reduce the scrap rate.

The mould was reengineered considering the SLM process and manufactured. Injection trials were carried out to validate expectations provided by injection simulations, which resulted on good quality parts and a significant decrease on cooling time, and, consequently, on the overall cycle time. The minimisation of scrap provided energy savings and time-to-market reduction.

The initial costs for AM tools still pose some doubts on decision-makers. The challenge of this study is to implement the methodology on a small-scale production and still ensure that benefits are achieved.

The case study selected for this research work is based on a parking sensor housing, which is a plastic part assembled on the vehicle’s front and rear bumpers, therefore, with aesthetics concerns. The part produced with the conventional mould exhibits surface defects that, to be minimised (not eliminated), require a longer packing time to diminish the sink marks.

The economic impact of the use of SLM is relevant despite the low batch size for the case study presented. Energy savings are achieved due to scrap reduction and shorter cycle time.

The systematic methodology proposed for prior evaluation of the advantages of conformal cooling is possible to be applied both on small scale and high production series.

Conformal cooling channels in additively manufactured molds are superior over conventional channels in terms of cooling control, part warpage and lead time. The heat transfer ability of cooling channels is determined by their geometry and surface roughness. Laser powder bed fusion manufactured channels have an inherent process-induced dross formation that may significantly alter the actual shape of nominal channels. Therefore, it is crucial to be able to predict the expected surface roughness and changes in the geometry of metal additively manufactured conformal cooling channels. The purpose of this paper is to present a new methodology for predicting the realistic design of laser powder bed fusion channels.

This study proposes a methodology for making nominal channel design more realistic by the implementation of roughness prediction models. The models are used for altering the nominal shape of a channel to its predicted shape by point cloud analysis and manipulation.

A straight channel is investigated as a simple case study and validated against X-ray computed tomography measurements. The modified channel geometry is reconstructed and meshed, resulting in a predicted, more realistic version of the nominal geometry. The methodology is successfully tested on a torus shape and a simple conformal cooling channel design. Finally, the methodology is validated through a cooling test experiment and comparison with simulations.

Accurate prediction of channel surface roughness and geometry would lead toward more accurate modeling of cooling performance.

A robust start to finish method for realistic geometrical prediction of metal additive manufacturing cooling channels has yet to be proposed. The current study seeks to fill the gap.

The purpose of this paper is to present a comparative study, regarding cooling time and dimensional accuracy, of conventional injection mold cooling channel layouts, using straight holes and a baffle, and free‐form fabricated (FFF) layout, manufactured by the direct‐metal rapid tooling (RT) method electron beam melting (EBM). Many other methods have been proven useful for RT, but the authors have not found any publications where EBM has been used to manufacture injection molding tools.

A test part was designed in order to replicate a common and important issue: inadequate cooling in deep cores. The part and the different cooling layouts were analyzed in an injection molding simulation software and the numerical results were compared with corresponding experimental results.

The analyses showed an improvement in both cooling time and dimensional accuracy in favor of conformal FFF cooling channels manufactured by EBM. The experimental results correlate well with the numerical tests, however with some discrepancies.

The results presented are based on the direct‐metal RT method EBM, and they were obtained using a specific test part.

This paper can be a useful aid when designing mold tools and especially when considering the usage of FFF cooling channels versus conventional cooling design. It can also serve as a reference when comparing the efficiency in terms of cooling time and dimensional accuracy between different layouts.

To determine the feasibility of sealing and finishing conformal cooling/heating channels in profiled edge laminae (PEL) rapid tooling (RT) using abrasive flow machining (AFM).

Sample PEL tools constructed of both aluminum and steel were designed and assembled for finishing by AFM. A simple design of experiments approach was utilized. Output parameters of interest included the material removal, surface roughness improvement and, most importantly, the ability to withstand a pressurized oil leak test.

AFM significantly improved the finish in the channels for aluminum and steel PEL tooling. Leak testing found that AFM also improved the sealing of both stacks at static pressures up to 690 kPa. The steel tooling appeared to benefit more from the AFM process. It has been postulated that the primary cause of the sealing is the plastic deformation of workpiece material in the plowing mode.

The conformal channels studied had a simple cross‐sectional geometry and straight runs. The PEL tools were only made of two materials. However, the research results show great promise for large RT, including thermoforming and composite forming molds where temperature control is a critical issue.

The ability to seal the interfaces between individual laminae expands the potential application of AFM tremendously. AFM also has the potential to finish a wide range of internal passages in a variety of RT.

AFM has been previously used for finishing stereolithography prototypes. This is the first known attempt to seal and finish channels in laminated RT using AFM.

This paper aims to verify whether selective laser melting (SLM) could be used for manufacturing mold with conformal cooling channels and determine whether the mechanical properties development of SLM manufacturing maraging steel mold would be beneficial to improve the quality of mold.

A series of block specimens and cylindrical tensile specimens are manufactured by SLM, and then are heat treated by solution treatment (ST) and solution treatment + aging treatment (ST + AT), respectively. The development of microstructure, microhardness and tensile strength of specimens is investigated. Then, a mold with conformal cooling channels is designed and manufactured by SLM and machined after ST with microhardness decreasing.

The morphology of microstructure varies widely under different heat treatment. The microhardness and tensile strength decrease after ST with cellular structure broken, which is conducive to mechanical finishing for mold to improve surface accuracy. After that, the hardness and strength of the mold increase significantly by AT with the precipitation of Ni3Mo, Fe2Mo and Ni3Ti particles. The maraging steel mold with conformal cooling channels can be manufactured by SLM successfully. And the surface accuracy of mold could be improved easily by machining.

Compared with the traditional mold with simple cooling channels, the mold with conformal cooling channels can be manufactured by SLM directly. The hardness of maraging steel mold manufactured by SLM can be reduced through ST, which is conducive to mechanical finishing for overcoming the defect of low precision of SLM directly manufacturing mold. This provides a new way for manufacturing mold of high quality.