In injection and die-casting molds, cooling channels are typically designed within the mold to improve cooling efficiency and maintain mold temperature balance. Compared to traditional cross-drilling methods, 3D-printed molds allow for the design of conformal cooling channels that are closer to the mold cavity surface, significantly reducing the injection molding cycle, effectively maintaining temperature balance, and minimizing the risk of product deformation, ultimately improving production efficiency and product quality.

However, conformal cooling channels in 3D-printed molds are more complex in shape, with rougher inner walls (Ra greater than 10 microns), which can present four risks during use: rusting, clogging, cracking, and reduced flow rate.

1. Rusting

   If the material used is not rust-resistant, the cooling channels are prone to rust and oxidation, reducing heat exchange efficiency and affecting the injection cycle.

2. Clogging

   Rust, impurities, and other deposits can accumulate on the rough surfaces of the cooling channels, leading to scale formation and blockage.

3. Cracking

   Localized stress corrosion due to rusting or surface roughness can cause cracking in the cooling channels.

4. Reduced Flow Rate

   Rust or surface roughness may impede water flow, negatively affecting the heat exchange process.

Based on more than a decade of experience in 3D-printed mold design and manufacturing, LAMOTEK offers various solutions to protect and maintain 3D-printed cooling channels:

Solution 01: Use of corrosion-resistant stainless steel printing materials

To improve print quality, LAMOTEK has independently developed several new materials tailored to meet the needs of mold printing. Among them, Anco-T material has excellent rust resistance, wear resistance, and fatigue strength, making it a high-performance mold steel suitable for most injection and die-casting molds. Anco-H material also offers good rust resistance, along with high strength, hardness, and wear resistance, making it ideal for printing delicate, thin-walled mold inserts and injection molds.

Solution 02: Polishing of cooling channels

LAMOTEK has developed an in-house polishing process for cooling channels, LCP, which achieves a surface roughness of Ra < 1μm after extreme polishing. This process effectively reduces the risk of clogging and cracking, slows the rate of rusting, and significantly improves and stabilizes water flow. Polishing is particularly important for non-rust-resistant materials and cooling channels with diameters less than 2mm.

Solution 03: Use of impurity filtration devices for cooling channels

LAMOTEK has independently developed the LIF impurity filtration device. Its unique design effectively filters out impurities from the water without affecting flow rate, preventing blockages in the cooling channels. This device is easy to install, clean, and replace, making it an essential component for conformal cooling channels in metal 3D printing.

Solution 04: Cooling channel cleaning and maintenance services

LAMOTEK not only focuses on preventive measures but also offers cooling channel cleaning and maintenance services. For already clogged channels, thorough cleaning is performed to remove rust, scale, and impurities, restoring the brightness of the inner walls of the channels.

LAMOTEK provides comprehensive protection solutions for 3D-printed conformal cooling channels, addressing issues related to rust and blockages to ensure their long-lasting durability.