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Boosting Efficiency and Economy in Injection Mold Tools with Topology Optimization, CFD Simulation and 3D Printing
Technology Category
- Analytics & Modeling - Digital Twin / Simulation
Applicable Industries
- Buildings
- Equipment & Machinery
Applicable Functions
- Facility Management
- Product Research & Development
Use Cases
- Additive Manufacturing
- Time Sensitive Networking
Services
- System Integration
The Challenge
The toolmaking industry, particularly in Europe and America, has been facing increased pricing pressure due to growing competition from Asian countries. This has led to a need for innovative and high-quality solutions that offer higher productivity and significantly lower costs per part compared to standard solutions. One of the key parameters for higher productivity is the cycle time, which can be optimized through conformal tempering. However, the challenge lies in reducing cycle time without compromising on the quality of the parts produced. The shorter the cycle time, the greater the number of components that can be manufactured within the same period, significantly increasing the facility’s overall productivity and economic viability.
About The Customer
The customer in this case study is PROTIQ GmbH, a spin-off from Phoenix Contact's business unit, Rapid Solutions. PROTIQ specializes in the production of individual tools made of different materials and offers its solutions globally. The company not only produces 3D printed parts but also leverages topology optimization and simulation to design the tools. PROTIQ's approach ensures that only the necessary amount of material is used, leading to lower production costs and improved handling of the injection mold in operation. The company has a platform where customers can upload their digital 3D data, calculate the price online, and have the final component delivered in no time.
The Solution
To address this challenge, the industry has increasingly turned to new manufacturing methods such as 3D printing (or additive manufacturing). Phoenix Contact, a company in the industry, started to evaluate these methods in 2009, initially using a polyjet printer and later adopting laser-sintering (plastic) and laser melting (metal) solutions. The company’s business unit, Rapid Solutions, delivered fast toolmaking solutions and prototypes. This approach proved successful, leading to the creation of a separate enterprise within Phoenix Contact, named PROTIQ GmbH. PROTIQ leverages topology optimization and simulation to design the tools. Based on load case descriptions and other boundary conditions, engineers are able to determine the optimal structure of the component prior to production. This approach ensures that only the necessary amount of material is used, leading to lower production costs and improved handling of the injection mold in operation.
Operational Impact
Quantitative Benefit
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