Published 03/20/2024

Mold Materials, 3D Printing Technologies for Next-Gen Moldmaking

As moldmaking advances, so too do the materials and processes involved in their efficient production, including these latest mold materials and 3D printing technologies.

Grace Nehls, Former MMT Editor

The injection molding process all starts with a metal mold. The type of material — whether it’s made of steel, aluminum or beryllium copper — used to make a mold is critical to the success of the final plastic part. The processes and technologies used to produce these molds are also just as pivotal.

Over the last few years, a focus on “next-generation” technologies has permeated the manufacturing industry — particularly regarding 3D printing and mold materials complementary to this process. Both material and process have quickly found a spot in mold building, whether it’s to aid in the production of an injection mold or even to repair it. Nonetheless, more traditional, high-quality tool steels also continue to maintain a key position for moldmakers.

Some of these developments are highlighted in the products roundup below. For a more comprehensive look at what is available to moldmakers, I encourage you to take a look at MMT’s “New Tech” section.

Sintered, Porous Mold Steel Eliminates Gas Buildup

Source | Molder’s World

Molder’s World Inc. draws attention to Vortex, a self-venting mold steel that it says is quickly becoming the industry standard. Specializing in self-venting mold steels since inception in 2001, Molder’s World is most well known as the preeminent distributor of Porcerax II prior to its discontinuation. Vortex, as its replacement, is claimed to be the most exciting development in the company’s 20+ year history.

Hybrid CAM Strategy Enables High-Quality, Efficient Mold Repair

As CAM technology requirements accelerate, and the market for additive/hybrid processes evolves, Open Mind highlights its hyperMILL for efficient repair or rework of molds.

Source | Oak Ridge National Laboratory (ORNL)

Tight-Tolerance, 100% Recyclable Steel Plate Processing

Source | Steel 21

Steel 21 provides competitively priced A36 and 4140 grade steel plate for plastic injection and compression molds using its patented “21 Micro Mill” process. Steel 21 flame-crafts pin plates, clamp plates, ejector plates, manifolds and rails to customer data (dwg or stp files) using high-definition plasma through 2" thicknesses and oxyfuel through 8" thicknesses.

Reliable, Efficient 3D Printer for High-Quality Tool Steel Components

Source | Plastic Manufacturing Technologies, LLC and Additive at Scale LLC

Trumpf Inc.’s TruPrint 2000, now featuring a larger, square build plate, is designed for reliable 3D printing of tool steels like maraging steel, crucial in tool and die manufacturing. It also comes with basic spot configuration with 80 µm.

Hybrid Multitasking Five-Axis Brings Subtractive, Additive Processes to Moldmakers

Source | Mazak USA

For combined productivity, flexibility and profitability, Mazak’s VC-500A/5X AM HWD five-axis machine delivers hybrid multitasking and hot wire deposition (HWD) part processing for manufacturers, including those in the moldmaking sector. The machine combines additive processes and subtractive multitasking to reduce lead times and part costs while it increases machining accuracy and part quality.

Maraging Stainless Steel Powder Engineered for Additive Manufacturing Applications

Edro Engineering and Specialty Steels, an exclusive distributor of Bohler tool steels, highlights Bohler M789 AMPO, a newly developed maraging stainless steel powder designed for additive manufacturing (AM) applications.

Source | Edro Engineering and Specialty Steels

Machine-Ready Blanks Help Mold Shops Reduce Production Time

Source | TCI Precision Metals

Machine-Ready Blanks from TCI Precision Metals help mold shops shorten setup time, reduce scrap and reduce in-house machining time by eliminating material preparation for a cavity, core, mold blocks and other components. Made-to-order, machine-ready blanks are produced to tight tolerances and exact customer specifications; they are guaranteed to arrive machine-ready for production.

Robotic Metal 3D Printer Automates, Augments AM, Repair and Cladding

Source | Meltio

Meltio launches the Meltio Robot Cell, a turnkey plug-and-ply robotic arm solution for safer, more reliable and highly accurate metal additive manufacturing (AM) of components autonomously, as well as part repair or a feature addition, attributes that have been seen to produce long-lasting multi-material molds in hybrid AM applications. The entire process is controlled with the company’s Meltio Space slicing software.

Tool Steel Improves the Efficiency of Molds, Injection Molding Using AM

AddUp will soon be releasing Printdur HCT, a tool steel optimized for injection molding that meets all customer requirements such as corrosion resistance, hardness and wear resistance for injection molding applications.

Source | AddUp

Turnkey Program for Additive Manufacturing

Source | EOS

EOS North America’s Additive Minds group launched its AM Turnkey consulting program, aimed at removing common roadblocks associated with industrial 3D printing by refining all necessary steps for successful additive manufacturing (AM) production. Upon conclusion of the consulting program, a proof of production guarantee is provided.