From print to performance: Enhancing additive manufacturing tools with PVD coatings for plastic molding
As additive manufacturing (AM) continues to revolutionize tool design and production, combining it with advanced surface technologies is opening new possibilities - particularly in plastic molding applications. Applying wear-resistant Physical Vapor Deposition (PVD) coatings to complex 3D printed tools significantly enhances their durability and performance. This synergy not only extends tool life but also improves productivity by reducing cycle times, machine downtime, and maintenance needs - making it a game-changer for high-efficiency manufacturing environments like bottle cap production. Read on to discover more!
Boosting tool longevity and productivity in plastic molding
Combining additive manufacturing (AM) with a subsequent physical vapor deposition (PVD) coating is an emerging trend toward improving the performance of complex 3D printed tools. Particularly in plastic molding applications, such as bottle cap production, wear-resistant PVD coating add durability and strength to 3D printed molds with integrated cooling channels produced from maraging steel (MS1) and thus contribute to minimized cycle times in production, improved productivity and minimized machine downtime and tool maintenance.
Advantages of additive manufacturing
Additive manufacturing of tools offers certain advantages compared to traditional or standard machining processes (summarized under the term subtractive manufacturing), which in particular include:
Design flexibility
Additive manufacturing enables the design of complex and customized tools that are difficult or impossible to manufacture using traditional manufacturing techniques.
Integration of cooling channels
Complex internal cooling channels can be integrated directly into the tool which contributes to optimized thermal management, e.g. in plastic molding applications that are sensitive to heat distribution and heat transfer.
Reduced lead time
Tools can be manufactured more quickly which enables faster prototyping (rapid prototyping, e.g. in the design phase) and contributes to reduced time-to-market for products.
Cost effective for low volume production
3D printing of tools has the potential to be more cost effective for manufacturing small quantities of highly customized tools.
Overcoming surface imperfections in 3D printed tools
The disadvantages of additive manufacturing, such as limitations from the material in terms of strength, durability and wear resistance and size constraints of tools stemming from the chamber size of commercially available 3D printers, play a minor role in manufacturing of plastic molding tools, e.g. in the production of bottle caps and in consideration of a subsequent physical vapor deposition (PVD) coating. The major challenge is the poor surface quality of 3D printed tools, which does not meet the standards of surfaces produced using traditional manufacturing techniques.
The typical layer-by-layer structure using common additive manufacturing techniques such as laser powder bed fusion (LPBF) and laser metal deposition (LMD) leave visible layer lines or a stepped surface texture. This becomes particularly challenging with regard to a subsequent PVD coating and ensuring sufficient adhesion between the tool and the PVD coating. This requires additional post-processing of the tool to ensure a higher surface quality in the form of smooth and uniform polished surfaces.
Tailored pre-coat treatments for enhanced 3D tool performance
Ionbond has developed customized pre-coat mechanical treatments for 3D printed tools based on its more than 50 years of experience in the coating services business. This allows Ionbond to offer its customers superior coating solutions on 3D printed dies. One success story with a proven track record is the combination of complex 3D printed molds with integrated cooling channels for producing bottle caps and Ionbond’s diamond-like carbon (DLC) coatings to reduce adhesive wear and release forces. This contributes to minimized cycle times in production, improved productivity and minimized machine downtime and tool maintenance.
Discover our coating solutions
Learn more about our DLC coating portfolio for plastic processing applications on our website and download our factsheets that provide you with more information about our coating solutions:
Plastic molding
Improve tool life and reduce scrap rates by improving product release, details and finish
Ionbond™ 41
Ionbond™ 42
Questions?
Discuss your challenges with Tobias Brögelmann
Dr. Ing. Tobias Brögelmann, Global Segment Manager Forming and Molding Tools, will be glad to support you.
We will get back to you as soon as possible.
Dr. Ing. Tobias Brögelmann
Global Segment Manager Forming and Molding
Dr. Ing. Tobias Brögelmann
Global Segment Manager Forming and Molding
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