1. Cyclustijdreductie bij kunststofspuitgieten Prof. dr. eng. Ludwig Cardon University College Ghent - CPMT research group Faculty of Applied Engineering Sciences Voskenslaan 362 – 9000 Gent 31 mei 2011

2. Centre forPolymer & Material Technologies 2 University College Ghent FacultyApplied Engineering Sciences INWE Departments of Electromechanics & Chemistry Schoonmeersstraat 52 B-9000 Gent – Belgium +32 9 24 24 292 www.cpmt.eu www.pmiconference.eu http://polymer.ugent.be

4. BSc & MSc courses

6. Mould making – hybrid moulds

7. Flow simulation (Moldex3D)

8. Biopolymers & biomedical applications

10. Fysico-Chemical analyses

11. Polymer processing

12. Mouldmaking (conventional & hybrid technologies)

13. Micro moulding

14. Flow analyses (Moldex 3D)

15. 3D Prototyping & Tooling

17. Technical biobased polymer processing

18. aRGPolymerChemistry& Technologyhttp://polymer.ugent.be Polymer materials and Biopolymers Prof. dr. P. Dubruel Polymer chemistry Prof. dr. F. Du Prez Appied material Sciences Prof. dr. ir. J. Degrieck Prof. dr.ir. W. Van Paepegem Design HoWest Cardiovascular Tissue Engineering Prof. dr. Van Nooten Infrared Thermal analyses Prof. dr. ir. De Mey Food Safety and quality « Pack4Food » Prof. dr. ir. F. Devlieghere Textiles Prof. dr. ir. G. Schoukens

19. Hybrid moulds for high quality plastic products Advantages and limitations Introduction Mould material selection and relation to polymer processing Parameters affecting the quality of the final product New tendencies in processing and mould making Case studies Discussion

21. Complex designed products

22. Multi layer foils/plates

23. Nano-fillers

24. Micro parts and moulds

25. Biobased and biodegradable polymersHYBRID MOULDS... BUT ...... this will result in new design rules and machine modifications.

26. What are hybrid moulds? Who will use this? Productdesigners new design methods Mould designers more freedom of design Mould makers  adapted machining parameters Polymer processors  adapted processing parameters 8

27. Actual status of mould development hybrid moulds conventional production technologies AM technologies Mould cooling related to cycle time and product quality optimal cooling channel layout conformal cooling mould material selection Product quality improvement e.g. sink marks degree of crystallisation tribology aspects (e.g. wearing)

28. Mould material selection Thermal characteristics of mould materials are very important Related to the core/cavity design strategy new part & mould design strategy “Unknown” material characteristics heat capacity Cp (DSC analysis) specific density r thermal conduction l thermal diffusivity a

29. Mould material selection method The metal groups: Conventionalmould materials Selective Laser Sintermaterials Selective Laser Meltingmaterials

30. Mould material selection method The metal groups: Conventionalmould materials Selective Laser Sintermaterials Selective Laser Meltingmaterials

31. Tribology aspects of hybrid moulds LaserForm100 - DS20 - Aluminium - 1730 before and after 25000 shots Wearing of DMLS submarine gate for coated and non-coated (right) inserts

32. Example of a hybrid mould

33. IR analysis of Prometal and Aluminium mould ProMetal 55 °C ProMetal & Aluminium 50 °C

34. Sensor analysis of Prometal and Aluminium mould ProMetal 55 °C ProMetal & Aluminium 50 °C

36. conventional mould making

37. AM technologies

38. “conventional” conformal cooling

40. No “warpage”

41. Faster cycle time

44. 20 The original mould

48. 23 The optimized mould

49. 24 The optimized mould conformal cooling insert in “maraging” steel via EOS SLM technology (LayerWise Belgium)

50. 25 The optimized mould “conventional”conformal cooling insert (VDS Technics Belgium)

52. Heat control for mould making

53. Extrusion and stretch blow moulding

54. Thermoforming

55. Micro injection moulding

57. Estimated cycle time (conformal cooling HM): 19s

58. Real HM cycle time: 32s

59. HM shell is not accurate in calculating cycle time

60. 16% of cycle time reduction

61. Annual total profit of 222.000 € (6.000.000 parts/year)

62. Modifiedcoolingnozzles for hot runner

63. Stretch blowbottle

64. Stretch blowbottle

65. Extrusion blowbottle Blow/cooling air simulation

66. Micro injection moulding 32

67. Micro injection moulding 33

68. 34 Questions? 5th International PMI Conference 12-14 September 2012_Ghent_Belgium www.pmiconference.EU University College Ghent Schoonmeersstraat 52 B-9000 Gent Belgium Centre for Polymer & MaterialTechnologies - CPMT +32 9 24 24 292 www.cpmt.eu ludwig.cardon@hogent.be