“IntelliTemp” research project provides new impetus for the die casting industry

The ‘IntelliTemp’ research project, funded by the Bavarian Research Foundation with around one million euros, has delivered ground-breaking results for the production of large-volume moulds. Under the leadership of the Technology Campus Parsberg-Lupburg, a joint research centre of the OTH Regensburg and the TH Deggendorf, and with the participation of the Bock Group, DMG Mori and FIT AG, innovative solutions were developed to make the production process in tool manufacturing more efficient.

Conventional manufacturing processes often reach their limits when it comes to optimising the temperature control of tools. As a rule, they are based on straight holes for cooling channels, which can only be adapted to the specific requirements of the respective component to a limited extent. ‘IntelliTemp’ therefore pursued the goal of finding new ways to better adapt the temperature control of tools to individual requirements.

Die casting tool in CAD section. — The CAD image shows the inner workings of the tool: The orange-colored areas made of a copper alloy ensure good heat dissipation. The combination with high-strength steel enables temperature control in line with requirements with excellent tool life properties.

Combination of additive and subtractive processes

The solution lay in a hybrid manufacturing process chain that combines additive and subtractive processes. For example, LMD (laser metal deposition) welding and milling were used to join materials with different thermal conductivity properties to create tools in a sandwich design. The use of copper alloys for channels, which ensure efficient heat dissipation, is particularly noteworthy.

The potential effects of this new technology on the die casting industry are very promising. Moulds can now be tempered more evenly, resulting in homogeneous cooling of the cast components. This not only reduces distortion and the risk of fire cracks, but also shortens cycle times by up to 40 per cent.

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Effective use of energy

According to Frank Ambrosius, Head of Tool Management at Bock, the ecological and economic benefits are enormous: ‘The newly developed approaches lead to optimised production processes with a more effective use of energy, which also leads to a reduction in CO2 emissions.’

Patrick Diederich, Managing Director at MG Mori, says: ‘We were able to gain numerous new insights into the processing of copper-based materials and the hybrid design of large-volume injection moulding and die-casting tools, and thus also significantly advance the technology of our Lastertec DED hybrid machines.’

‘This project has made a valuable contribution to the research and development of additively manufactured master moulds,’ adds Carl Fruth, CEO of FIT AG.

For the die casting industry, which is increasingly focussing on sustainability and efficiency, ‘IntelliTemp’ represents a step forward. Especially in the field of aluminium die casting, where fast cycle times and high material stresses are commonplace, this technology could set a standard in the future. The use of additive manufacturing processes, which make it possible to produce components with complex geometries and variable thermal requirements, is becoming increasingly important.

Competitive advantages through cooperation

The project also illustrates the importance of collaboration between science and industry, in this case the Parsberg-Lupburg Technology Campus under the scientific leadership of Andrey Prihodovsky and all the partners in the network. Such collaborations could bring further innovations to the industry in the coming years and secure competitive advantages for companies that focus on these technologies at an early stage.

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