Evaluation of AlSi10Mg injection moulding inserts with conformal cooling channels

Purpose This paper aims to investigate and compares the performance of mould inserts with conformal cooling channels (CCC), fabricated via additive manufacturing (AM), and conventional cooling systems, both made from aluminium alloys. The comparative analysis encompasses simulation results, critical manufacturing considerations and part quality, focusing on warpage and crystallinity. Design/methodology/approach A test part was designed to assess warpage and crystallinity using conventional and conformal cooling systems. Six CCC configurations were simulated, with one selected due to its improved performance. Injection moulding simulations enabled to compare the performance between conventional and conformal cooling systems. Structural simulation analysis of the AM mould with CCC ensured mechanical suitability and mass reduction through topology optimization and lattice structures integration. Mould inserts were manufactured, and parts were fabricated with amorphous and semicrystalline materials to compare warpage and crystallinity. Findings AM moulding inserts with CCC and topology optimization achieved over 50% material reduction, a 15% decrease in mass and 36% waste savings. CCC lowered mould insert temperatures by 4.8% on average, reducing crystallinity by 4.1 ± 2.89% due to improved cooling rates. Originality/value Most studies on CCC focus on steel-based moulding inserts. This research investigates aluminium alloys for conventional and conformal cooling systems, leveraging their superior thermal conductivity. The study combines simulation analysis with an evaluation of injected plastic part quality for semicrystalline and amorphous polymers. Future work encompasses exploring variations of the selected CCC design.