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SLM Metal 3D Printed Conformal Cooling Injection Mold

Integrated mold with built-in irregularly shaped water channels, eliminating the need for disassembly, drilling, and grooving. It can be designed as a conformal cooling water channel, perfectly conforming to the contours of the product cavity. This is a core structural advantage of 3D printing, as traditional drilling cannot achieve such irregularly shaped, surrounding pipes. The water channels are flush with the product surface, eliminating cooling dead zones, reducing injection cooling time by 30% to 55%, and increasing production efficiency by over 35%. Uniform temperature distribution throughout the mold effectively solves injection molding defects such as warpage, shrinkage marks, bubbles, and cracking, significantly improving yield. Uniform heat dissipation reduces fatigue wear due to alternating hot and cold temperatures, increasing mold lifespan by 30% to 50% compared to traditional straight-hole water channels.

Widely used in injection molds for appliance housings, automotive plastic parts, precision electronic plastic parts, and irregularly shaped parts for daily necessities, especially for deep-cavity, thin-walled, and irregularly curved products that are difficult to cool.

Printable Materials

It can form over 50 types of materials, including AlSi10Mg, AlSi7Mg, TC4, TA15, GH4169, GH3625, GH5188, GH3128, GH3536, 304, 316L, 17-4PH, H13, 18Ni300, CX, and CoCrMo.

The precision of the products can generally be controlled below 0.05mm, the density can reach 99.5-99.97%, and the surface roughness Ra 5-9 micrometers. The table below shows the material properties of commonly used metallic materials using selective laser melting technology:

 

Metal Material Name

316L Stainless Steel

AlSi10Mg Aluminum Alloy

TC4 Titanium Alloy

MS1 Mold Steel

GH4169 Nickel-based Superalloy

Ultimate Tensile Strength (Rm)

620±50MPa

345±10MPa (XY)

350±10MPa (Z)

1050±20MPa

1950±100MPa

1400±100MPa

Yield Strength (Rp0.2)

560±50MPa

230±15MPa (XY)

230±15MPa (Z)

1000±20MPa

1990±100MPa

1150±100MPa

Hardness

85HRB

-

-

50-56HRC

47HRC

Elongation (A%)

36±4%

12±2% (XY)

11±2% (Z)

14±1% (XY)

15±1% (Z)

4±2%

15±3%

Application Scope:

Metal wrenches, tooling fixtures, complex sheet metal parts and other products

Housing parts with low comprehensive strength requirements for weight reduction, automotive heat dissipation components, etc.

High-strength and lightweight components for racing cars and sports cars

Mainly used for manufacturing plastic molds with high precision, super mirror surface, complex cavities and large cross-sections

Discs, rings, shafts, blades, fasteners, elastic components, gas pipelines, sealing elements, etc.

 

The above material properties are test values ​​for 3D printed workpieces in a "heat-treated state". In addition to the commonly used material properties mentioned above, the Jingye Additive Manufacturing team can develop printing process parameter packages for new materials according to customer needs.

Product Application Scenarios

Currently, metal 3D printing technology has been widely applied in aerospace, industrial molds, electronics and energy, education and scientific research, and other fields. In addition, 3D printing technology has mature applications in everyday life, such as automotive parts manufacturing, conformal cooling channels/thermoplastic molds, and orthopedic implants.

Solving Customer Pain Points

1. Mold Industry

Pain Point 1: Uneven cooling in injection molding and die casting molds, product warping, and slow molding; SLM conformal cooling channels provide uniform temperature control, significantly reducing defects;

Pain Point 2: Complex and irregularly shaped mold inserts are difficult to process and have long cycles; SLM directly molds inserts, eliminating multiple milling processes.

 

2. Aerospace

Pain Point 1: Insufficient cooling of high-temperature engine components, resulting in low thermal efficiency; integrated complex cooling channels improve combustion efficiency;

Pain Point 2: Excessive aircraft weight limits carrying capacity; lattice lightweight structures significantly reduce weight;

Pain Point 3: Leakage and vibration failure during assembly of multiple parts; integrated molding eliminates weak points in welds.

 

3. Medical Orthopedics and Dentistry

Pain Point 1: Mismatch between standard prostheses and patient's bones, leading to postoperative loosening; SLM personalized biomimetic porous structure improves bone ingrowth;

Pain Point 2: Porous fusion scaffolds cannot be fabricated using traditional processes; implants are prone to stress shielding and osteoporosis.

 

4. New Energy Heat Dissipation (Aluminum Alloy)

Pain Point: Traditional heat dissipation pipe layout is limited, resulting in low heat dissipation efficiency; SLM one-piece molded dense irregular heat dissipation array doubles the heat exchange capacity.

Comparison of Technical Advantages

The following table compares SLM metal 3D printing technology with other additive manufacturing technologies:

 

Comparative Process

Advantages

Disadvantages

vs. DED (Laser Powder Feeding)

1. High forming accuracy and excellent surface quality, able to fabricate precision structures such as micro flow channels and thin-walled lattices;

2. Powder bed fusion delivers higher part density with fewer internal defects;

3. Consistent forming performance for individual parts, suitable for batch prototyping of small & medium precision components.

1. Limited build dimension, unable to process large components;

2. Higher costs for equipment and metal powder, poor economic efficiency for large-size parts;

3. Incapable of repairing or cladding existing parts.

 

vs. EBM (Electron Beam Melting)

1. Far superior forming accuracy and surface finish to EBM, less post-machining allowance needed;

2. No vacuum chamber required, simpler equipment maintenance, wider range of available materials (aluminum, copper, mold steels are all compatible);

3. More stable printing speed with higher productivity for small-sized parts.

1. Fast laser cooling leads to high residual stress inside parts, so heat treatment is compulsory;

2. Higher risk of stress cracking for superalloy printing compared with EBM.

 

vs. MIM (Metal Injection Molding)

1. No injection mold development required, low cost and short lead time for single pieces, small batches and new product iterations;

2. Enables complex structures including internal conformal cooling channels and hollow lattices that cannot be realized by MIM;

3. Better mechanical properties with density close to forgings, applicable for load-bearing components working under high temperature and high pressure.

1. Higher unit cost for mass-produced standard small parts than MIM;

2. Lower production efficiency than MIM, not fit for mass production of 100,000-piece scale.

vs. Non-Metal 3D Printing (FDM/SLA)

1. Fully metal finished parts with outstanding strength, high temperature resistance, corrosion resistance, thermal and electrical conductivity;

2. Can be directly applied to tooling, molds and aerospace load-bearing structures to meet industrial load-bearing service conditions.

1. Extremely high costs of equipment, metal powder and daily operation;

2. Complicated process flow, requiring multiple auxiliary procedures including heat treatment, flaw detection and post-machining.

 

The comparison in the table above shows that the comprehensive advantages of SLM technology are:

1. High precision and strong detail expression; the strongest ability to integrate complex internal cavities and lightweight dot matrix molding;

2. High metal density and excellent mechanical properties; suitable for molds, aerospace, and medical precision parts;

3. Wide material coverage; stainless steel, titanium, aluminum, high-temperature alloys, and mold steel can all be molded;

4. High utilization rate of precious metal materials; combined with proprietary heat treatment, machining, and testing equipment, finished products can be delivered in a one-stop manner.

Successful Cases

1. SLM Metal 3D Printed Conformal Cooling Injection Mold:

An integrated mold with built-in irregularly shaped cooling channels, eliminating the need for disassembly, drilling, and grooving. It can be designed as a conformal cooling channel, perfectly conforming to the contours of the product cavity. This is a core structural advantage of 3D printing, as traditional drilling cannot achieve such irregularly shaped, surrounding pipes. The water channels are flush with the product surface, eliminating cooling dead zones, reducing injection cooling time by 30% to 55%, and increasing production efficiency by over 35%. Uniform temperature distribution throughout the mold effectively solves injection molding defects such as warpage, shrinkage marks, bubbles, and cracking, significantly improving yield. Uniform heat dissipation reduces fatigue wear due to alternating hot and cold temperatures, increasing mold lifespan by 30% to 50% compared to traditional straight-hole water channels.

This type of product is widely used in injection molds for appliance housings, automotive plastic parts, precision electronic plastic parts, and irregularly shaped parts for daily necessities, especially for deep-cavity, thin-walled, and irregularly curved products that are difficult to cool.

 

2. Lightweight Design:

We printed a single-piece component for a client, featuring a double-layer thin-walled metal skin and an internal three-dimensional solid-centered cubic lattice core. The lattice rod diameter is only 0.5mm. It is formed in one piece using SLM (Silicon-Modulated Laminate) without any adhesive or welded interlayers. This reduces weight by 30% to 50% while maintaining the same bending stiffness. It also combines multiple functions such as load-bearing, lightweighting, heat dissipation, and energy absorption.

Services Offered

We are a professional one-stop service provider for SLM metal 3D printing, integrating model design and processing, metal forming, heat treatment, precision machining, and non-destructive/mechanical/dimensional inspection. We can customize lattice skins, conformal cooling channels, and complex aerospace precision metal parts, with in-house production and delivery of finished products.

 

1. Additive Molding Processing Services

Utilizing Selective Laser Melting (SLM) technology, we can process metal powders such as Ti6Al4V, AlSi10Mg, 316L, 18Ni martensitic steel, GH high-temperature alloys, and copper-chromium-zirconium. We can integrally mold lattice sandwich skins, built-in conformal cooling channels, integrated hydraulic valve bodies, topological lightweight structures, high-temperature heat exchange components, and porous medical implants—parts that are difficult to manufacture using traditional processes. We support single-piece R&D prototypes and small- to medium-batch production of functional parts.

 

2. Post-processing Services

Utilizing our own heat treatment equipment, we perform stress relief and solution aging treatments to eliminate residual printing stress. We separate the substrate and remove supports via wire cutting. CNC machining is then used to finish assembly references, threads, and mating surfaces, supplemented by sandblasting and grinding to meet assembly requirements.

 

3. Finished Product Inspection and Quality Control Services

Equipped with industrial X-ray flaw detection equipment, universal tensile testing machines, and coordinate measuring machines, we can perform non-destructive testing of internal defects, mechanical property testing, and full inspection of geometric dimensions and tolerances for components. Complete inspection records are maintained to ensure that the mechanical properties and dimensional accuracy of components meet usage standards.

 

4. Technical Support Services

We provide technical support including 3D model design, printing process planning, process optimization, and small-batch iterative trial production. This enables one-stop delivery from design to qualified finished products, reducing outsourcing and shortening the production cycle.

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Responsible Person

Responsible Person

Person In Charge:

Meng Weihua, +86 150 3207 1231

Contact Us

Contact Us

Tel.: +86 0311 8289 8906 / +86 150 3207 1231

E-mail: jyzczz@hbjyjt.com

Fax: 0311-82898906

Address: Jingye Industrial Park, Nandian Town, Pingshan County, Shijiazhuang City, Hebei Province, China

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