3D-printed conformal cooling channels for extended tooling life

"CastAlum is an internationally acclaimed aluminium die caster, located in Mid Wales. The company supplies parts to the UK, Germany, Poland, Canada and Mexico and recently won its first order from a truck manufacturer in the Far East. Today, one in ten vehicles produced in Europe has a steering gear housing manufactured by CastAlum in Welshpool.

High-pressure aluminium die-casting (HPADC) is an established technology superior to other casting techniques for serial manufacture of lightweight thin-wall components, physical properties in high-demand by the automotive components sector. However, inadequate cooling of dies and cores can lead to 'Hot Cracking', connected porosity, and high levels of rejects.

To tackle the industry wide challenge of hot cracking, connected porosity and high reject rate, CastAlum are exploiting digital design processes and state of the art manufacturing techniques to optimise die cooling/heat transfer and extend tooling life from 100,000 to 200,000 shots. The resultant technology will also reduce reject rate and enable manufacture of higher quality, lighter products for the automotive sector.

CastAlum are collaborating with Renishaw PLC, one of the world's leading engineering and scientific technology companies, and The School of Mechanical, Aerospace and Automotive Engineering at Coventry University. Our consortium brings together leading experts in additive manufacture, material processing, thermodynamic flow modelling and CAD/CAM processes.

Successful project delivery will cement our reputation as leading innovators within the industry and is the first step in an ambitious growth strategy to nearly double our market share."