Repair and manufacture of multi-material die-cast cores with internal cooling channels

The repair of worn die-cast cores occupies die-casters worldwide. Due to the cost-intensive, partially manual repair process in connection with the limited service life compared to the original tool molds, there is a great potential for optimization. However, this can be fully exploited using the latest additive manufacturing technology. With DMG MORI DED hybrid machines, service life can be increased by a factor of up to 3 and throughput times reduced by up to 80%. The big advantage of using hybrid machines for these applications is complete machining in a single setup. Worn component areas are removed by milling, the new material is applied again with the laser processing head and then milled to the final dimensions - in the same clamping, on one machine. Time-consuming reclamping or subsequent hardening processes are not necessary.
Additive manufacturing also offers numerous advantages in the production of new high-performance die-cast cores. The possibility of combining different materials on one component (so-called multi-material) is only possible through additive manufacturing. Through the combination with internal cooling channels, the quality can be increased due to the significantly increased heat dissipation and thus the rejects can be significantly reduced at the same time. In addition to the economic component, this also contributes to reducing the CO2 footprint.
We look forward to welcoming you as a listener and offer you the opportunity to discuss your task in a solution-oriented manner after the presentation.