Metal 3D printing helps Innomia increase the production of auto parts by 17%

Scott J Grunewald

With both safety and weight/fuel efficiency concerns being high priorities for automobile manufacturers, plastic components are being used in modern cars more than ever. Unfortunately plastic components can often feel or look cheap, leading to customer dissatisfaction, however in the last few years new advanced materials have been developed to improve the visual appeal and surface texture of plastics. These new plastic materials may look and feel better to consumers, but for manufacturers they can often be difficult to work with, especially when using traditional injection molding techniques. This can often be compounded when manufacturers are required to make plastic components with complex or unusual geometries, as is becoming increasingly more common.

The central front armrest and the tool needed to cool the injection molded part.

The EOSINT M 270 direct metal laser sintering 3D printer.

When Innomia tackled the problems that Magna was having with their tooling systems, their first priority was the development of a new tool with an optimized heat removal cooling system. The company decided to 3D print the new insert using their EOS direct metal laser sintering (DMLS) 3D printer, which gives them the ability to fabricate components with virtually any external and internal geometry. The Innomia team designed their new insert with an integrated system of conformal cooling channels that were only 3mm wide. The part was 3D printed on an EOSINT M 270 using a maraging steel powder material, a low-carbon metal that is known for exceptional strength.

The final printed insert still on the printing bed.

“The DMLS process enabled us to manufacture an extremely durable component, while at the same time successfully retain the proven advantages of AM in terms of design flexibility. Thanks to the conformal cooling channels integrated into the component with optimum precision, we have inexpensively resolved the main challenge of the production process,” explained Innomia CEO Luboš Rozkošný.

In addition to the new, more durable insert, Innomia was also able to additionally harden the final part using a post-treatment that resulted in a high level of wear resistance and much lower maintenance costs. The new uniform cooling channels in the tool increased the productivity and speed of the production cycle by 17%. Additionally, the problem with component deformation is no longer an issue and the final part quality and repeatability have both increased.

“There is stiff competition in the European automobile industry. That is why it is very important for us to be able to produce components to the highest quality standards at the lowest price. The issue of injection mould cooling was something that we have been trying to deal with for a long time. We knew how we wanted improved products to look, but realising it was just not possible using conventional manufacturing methods. Additive manufacturing has allowed us to make the breakthrough and we are very happy with the results at every level. Maintenance, quality of the end product, costs, heat dissipation – it has been the perfect project,” said head of tool maintenance for Magna, Pavel Strnadek.

Thanks to metal 3D printing technology, not only was the complex plastic car component easier than ever to injection mold at a higher level of quality, but it was faster, cheaper and more efficient. The final result of the new 3D printed tool was a savings of €20,000 after fabricating 370,000 parts.