Conformal cooling in new moulding tool

3D TM

Ultra Cool

1www.ultracool3d.com© Ultra Cool 3D 2009 Confidential, Patent Pending

Jayesh ModiManaging DirectorUltra Cool 3D [email protected]+61 410 095 160

Reducing Cycle Times

3D TM

Ultra Cool

2www.ultracool3d.com© Ultra Cool 3D 2009 Confidential, Patent Pending

Ultra Cool 3D TM is a patent pending innovative technology developed in Australia

Ultra Cool 3D TM will revolutionize the way you will build tooling in future to increase profits and reduce your carbon footprint

Introducing Ultra Cool 3DTM

3D TM

Ultra Cool

3www.ultracool3d.com© Ultra Cool 3D 2009 Confidential, Patent Pending

Substantially reduce cycle times Improve part quality

› Reduce molded-in stresses and warpage› Control process drift› Shorten new tool commissioning time

Sustainability› Reduced energy & material consumption› Get ready to minimize your carbon tax

Realize those profits.

3D TM

Ultra Cool

4www.ultracool3d.com© Ultra Cool 3D 2009 Confidential, Patent Pending

Very high temperature gradient 40 sec cycle time High warpage

Simplified cooling causing heat build-

up

50% reduction targetHousing Thermal

Image

Case

1

3D TM

Ultra Cool

5www.ultracool3d.com© Ultra Cool 3D 2009 Confidential, Patent Pending

Very high temperature gradient 50 sec cycle time + cooling fixture High warpage

Electronic Housing Thermal Image

Case

2

Simplified cooling causing heat build-

up

40% reduction target

3D TM

Ultra Cool

6www.ultracool3d.com© Ultra Cool 3D 2009 Confidential, Patent Pending

DistanceDistanceDistance

3D TM

Ultra Cool

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Distance- cooling channel maximum distance to mold wall.

Distance- cooling channel minimum distance to mold wall.

Distance- cooling channel pitch distance.

3D TM

Ultra Cool

8www.ultracool3d.com© Ultra Cool 3D 2009 Confidential, Patent Pending

3D TM

Ultra Cool

9www.ultracool3d.com© Ultra Cool 3D 2009 Confidential, Patent Pending

54 % extra cycle timeProfit lost !

23o C differentialWarpage !

3D TM

Ultra Cool

10www.ultracool3d.com© Ultra Cool 3D 2009 Confidential, Patent Pending

Process drift (100+ shots to stabilise)Poor Quality !

23o C differential- WarpageReversal from -7 o C to + 23o C Varying shrinkage !

-7 o C

+ 23o C

3D TM

Ultra Cool

11www.ultracool3d.com© Ultra Cool 3D 2009 Confidential, Patent Pending

Conventional 2D Cooling Near Part Multi Zone 3D Cooling

The Solution is….. 3D Near Part Cooling

Case

1

3D TM

Ultra Cool

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Conventional 2D Cooling Near Part Multi Zone 3D Cooling Bring in the profits

3D cooling

Case

2

3D TM

Ultra Cool

13www.ultracool3d.com© Ultra Cool 3D 2009 Confidential, Patent Pending

How much can I save with 3D?Typical Case study of injection molded part Part Name: Frame Lower

Part No.:  

No. of cavities 4 4 

Machine size: 500 Tons 500 Tons 

 Current Proposed

Current cycle time (sec.) 60 40 

Total no. of parts per hour 240 360 

Machine cost per hour 120 120 

Overhead @ % of machine cost 50 50 

Effective process cost per piece 0.75 0.50 Saving process cost 33%

Monthly production (20 days at 22 hours per day) 105600 158400 Production Up 50%

Savings per month (20 days at 22 hours/day) $ 39,600    

Payback periods as low as 2-4 months

Bring in the profits

3D TM

Ultra Cool

14www.ultracool3d.com© Ultra Cool 3D 2009 Confidential, Patent Pending

Significantly reduced cycle times Improved part quality Increased profits

Surprisingly short payback periods

3D TM

Ultra Cool

15www.ultracool3d.com© Ultra Cool 3D 2009 Confidential, Patent Pending

Gap analysis Design and manufacture cavity and core inserts

with conformal 3D cooling› We will work with your toolmaker

Full consultancy including Infra Red Imaging Training

3D TM

Ultra Cool

16www.ultracool3d.com© Ultra Cool 3D 2009 Confidential, Patent Pending

Over 80 years combined experience - gain from our expertise

We will participate in the entire process from design review to series production

We will energise all stake holders Extensive network of industry specialists

3D TM

Ultra Cool

17www.ultracool3d.com© Ultra Cool 3D 2009 Confidential, Patent Pending

Injection molding, Blow molding, RIM, DMC, Rubber

High Pressure Die casting Hot forging Glass Any thermal management challenges

3D TM

Ultra Cool

18www.ultracool3d.com© Ultra Cool 3D 2009 Confidential, Patent Pending

•Our proprietary algorithm is adapted from original research developed at MIT.•We design for six different criterions including tool strength, mold deflection, coolant temp., pressure drop, uniform cooling of part, part eject temperature and glass transition temperature.•This ensures optimised design that will yield shortest cycle times with exacting and uniform cooling of parts ensuring best possible crystallisation, minimal residual stress and warpage.

3D TM

Ultra Cool

19www.ultracool3d.com© Ultra Cool 3D 2009 Confidential, Patent Pending

Confidentiality Note: Intellectual property protection is sought for various stages of our products, they are protected under various patents in various stages of application. No part of this presentation or technologies described herein may be copied, reproduced without express written permission of its proprietors.