CAD/CAM Software Generates Unique Additive Tool Paths for Mold Cooling Channels

Open Mind Technologies, a developer of CAD/CAM software solutions worldwide, offers hyperMILL Additive Manufacturing which has a wide range of capabilities for additive and hybrid processes, including the ability to create additive tool paths from all available toolpath strategies. This functionality is said to be exceptionally productive for directed energy deposition (DED) processes for additive/hybrid manufacturing in a multi-axis machining or robot delivery system setup.

A multi-axis application where having access to all available tool paths is a key advantage is when embedding conformal cooling channels into a mold, which are typically positioned at a uniform distance. Another use case involves designing geometric features (such as zigzags) to generate cooling changes that are not manufacturable by standard methods such as traditional deep-hole drilling techniques. Since powder or wire deposition needs to adhere to a base material, multi-axis orientation control is critical to building organically shaped channels, Open Mind notes. Furthermore, regarding hybrid platforms, final subtractive machining operations can occur in the same setup as the additive processes. This also enables the engineer to interleave additive and subtractive operations, which greatly increases the breadth of additive applications.

The images and video demonstrate two applications where hyperMILL Additive Manufacturing tool paths were used for creating conformal cooling channels in molds. The first example is a mold with multiple gas caps (opening image), and the second is an injection mold screw (at right). The assemblies, including the shaped channels, have been confirmed with metallurgical tests for material properties. The conformal cooling channels have also passed initial tests regarding fluid dynamics.