Smart Molding International 1-2024

34 smart_molding international 1/2024 molds and tooling Bridging medical product development to production with additive Westminster Tool used additive manufacturing to quickly create a production-level mold in a fraction of the time compared to traditional machining methods. The project required over 40 swipe-by shut offs, a testament to its complexity. S ince July of 2022 Westminster Tool has pushed the limits of the new Mantle Beta additive manufacturing machine, worked with Mantle to improve the machine’s quality and efficiency, and completed numerous trials to identify ways to add value using this technology. One of Westminster Tool team greatest success stories is utilizing Mantle’s technology to quickly deliver production-representative parts for a medical OEM to complete biocompatibility and functional testing. This included molding over 7,000 pieces for development trials. Westminster Tool specialists were then able to implement the lessons learned from the prototype mold build into a production tool, allowing them to save over 30% in design costs. Most of all, this tool had over 40 swipe-by shut off conditions, something they were concerned a printed technology wouldn’t be able to handle. Traditionally, this project would have required at least 8 weeks for manufacturing, requiring over 30 electrode shapes alone. THE CHALLENGE A largemedical device OEMneeded production-representative parts quickly in order to complete biocompatibility and functional testing. Development trials needed to be completed before large-scale production could begin. Secondly, the complex part design included over 40 swipe-by shut off conditions, posing major risks to quality. THE SOLUTION Westminster Tool used metal additive manufacturing to quickly produce H13-equivalent, production-level cavities in a fraction of the time compared to traditional machining methods. By spending more time on risk mitigation upfront with the printed prototype mold, the customer was able to save over 30% in design costs for production tooling. PHASE ONE: Production-Quality Prototype Parts in Under 4 Weeks The first step was designing a prototype mold using MUD frame inserts and H13-equivalent printed cavities to replicate a production environment as quickly as possible. To do this, Westminster Tool used Mantle’s Trueshape Technology to print a top and bottom cavity. While the cavities were printed and sintered over 8 days, the team finalized a post-print machining strategy, ordered MUD inserts and began the insert modifications. The cavities required 55 hours of post machining including the following: • Grinding the bottom of the blocks to have a flat base to start from. • Squaring the blocks to bring molding geometry to center using hardmill. • EDM wiring ejector pin holes. • Tapping water lines and bolt holes. • Hard-milling and EDMing difficult swipe by areas (6 areas total). These operations took an additional 1.5 weeks before Westminster Tool specialists were ready for final assembly and molding: resulting in molded parts within 4 weeks. The parts had minimal flash, and all critical dimensions were within +/- 0.003”. The parts were then molded in batches for development and biocompatibility testing in two different materials. The first was an ABS and the second was a PC/ABS blend. Ultimately over 7,000 pieces were produced for the customers development needs. PHASE TWO: Reviewing Lessons Learned The first of several lessons learned involved warp and sink challenges. Westminster Tool specialists were able to improve Picture: Westminster Tool