WINNER: 3D Printed Die Components
2019 - PACE Award Winner
What: 3D printing makes dies more robust and flexible
Innovation: Using additive manufacturing to improve cooling while production dies are being cast reduces porosity and increases die strength, while also reducing scrap rates. Exco’s new design method, powder bed fusion technology, produces complex designs for high-pressure die casting tooling. This offers much lower cycle times with quicker solidification and improved casting quality.
First Customer: Spartan Light Metal Products for Toyota
Judge's Citation: Exco's hybrid additive manufacturing process using maraging steel delivers conformally cooled tooling to the high-pressure die casting industry. The result is an 80 percent reduction of die build times, a 50 percent reduction of part scrap and increasing tool life by at least a factor of three. Shorter setup times because of conformally cooled tooling and longer tool life reduce downtime by more than 13 percent. The additive manufacturing process can save automotive die casters millions of dollars a year. Hybridizing makes production more viable, increases accessibility to a larger portion of the tooling market and creates a more precise and increased capability for high-pressure die casting.
Web site: excoeng.com