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REDUCING CYCLE TIMES AND IMPROVING PART QUALITY

Jayesh Modi Managing Director, UltraCool3D Jayesh@UltraCool3D.com +61 410 095 160


Warpage, Long Cycle Times, Tolerances • Spending endless hours in trying to control Warpage? • Even after all efforts, residual stress in parts made part unacceptable in field service, can you afford brand damage?

Confidential, Patent Pending www.ultracool3d.com

© Ultra Cool 3D 2011


Development Possibilities – Automotive siren Case 1

• Very high temperature gradient • 40 sec cycle time • High warpage

Simplified cooling causing heat build-up 50% cycle time reduction target

Confidential, Patent Pending www.ultracool3d.com

© Ultra Cool 3D 2011


Development Possibilities – Automotive ECU Case 2

• Very high temperature gradient • 50 sec cycle time • High warpage

Simplified cooling causing heat build-up 40% cycle time reduction target

Confidential, Patent Pending www.ultracool3d.com

© Ultra Cool 3D 2011


Case 3

Development Possibilities – Automotive Mirror

Simple IR image far more effective than single point pyrometers used.

Confidential, Patent Pending www.ultracool3d.com

Š Ultra Cool 3D 2011


Case 4

Development Possibilities – Air Intake Manifold

Excessive temperature variation, long cycle time, warpage.

Confidential, Patent Pending www.ultracool3d.com

Š Ultra Cool 3D 2011


Case 5

Success Story Rigid Packaging Husky Analysis, 12.6 sec. Cycle time

(Husky Seminar Notes)

Confidential, Patent Pending www.ultracool3d.com

Š Ultra Cool 3D 2011


Case 6

Tool Diagnostic Rigid Packaging Blocked cooling channel, product quality issues.

Confidential, Patent Pending www.ultracool3d.com

Š Ultra Cool 3D 2011


Realize those profits Ultra Cool 3D’s rigorous design methodology aims to deliver a remarkable thermal response. With proprietary algorithm based on published research from MIT, UltraCool3D will help control: Quality - Warpage - Weld lines - Weight - Cycle time

COST

Confidential, Patent Pending www.ultracool3d.com

Š Ultra Cool 3D 2011


Solution UltraCool3D • Substantially reduce cycle times • Improve part quality • Reduce molded-in stresses and warpage • Control process drift • Shorten new tool commissioning time • Sustainability

• Reduced energy & material consumption • Get ready to minimize your carbon tax

Confidential, Patent Pending www.ultracool3d.com

© Ultra Cool 3D 2011


ProjectFood Container Lid Finished poppet. t3D cooling on poppet head.

Very small temperature differential over entire part, leading to great warpage control and shortest possible cycle time.

Confidential, Patent Pending www.ultracool3d.com

Š Ultra Cool 3D 2011


ProjectLight Switch Bezel 30% Cycle time reduction target.

Conventional cooling Conformal Cooling

Confidential, Patent Pending www.ultracool3d.com

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Project“Rib Cage” 3D Cooling

Confidential, Patent Pending www.ultracool3d.com

© Ultra Cool 3D 2011


What causes long cycle times

In addition to part thickness‌. Distance- cooling channel

- maximum distance to mold wall. - minimum distance to mold wall. - pitch distance.

Confidential, Patent Pending www.ultracool3d.com

Š Ultra Cool 3D 2011


Why does it matter? 54 % extra cycle time Profit lost !

Confidential, Patent Pending www.ultracool3d.com

Š Ultra Cool 3D 2011

o

23 C differential Warpage !


Why does it matter? Process drift (100+ shots to stabilise) Poor Quality !

o

o

+ 23 C o

-7 C

23 C differentialWarpage Reversal from o o -7 C to + 23 C Un-stable tool

Confidential, Patent Pending www.ultracool3d.com

Š Ultra Cool 3D 2011


Proprietary Software o Based on algorithm developed at MIT. o Design for six different criteria- uniform cooling of part, part eject temperatures, tool strength, coolant temp., pressure drop.

o This ensures- shortest cycle times with uniform cooling of parts ensuring best possible crystallisation, minimal residual stress and warpage. o We can help- gap analysis, tooling specification, design review, tooling manufacture.

Confidential, Patent Pending www.ultracool3d.com

Š Ultra Cool 3D 2011


Proprietary Software ….. at your service

Confidential, Patent Pending www.ultracool3d.com

© Ultra Cool 3D 2011


Quality Built-in • Our technology is developed in Australia and analysis carried out at CSIRO and Dept. of Defense facilities by use of advanced scanning electron microscopes.

Confidential, Patent Pending www.ultracool3d.com

Š Ultra Cool 3D 2011


Mission Statement At UltraCool3D we are dedicated to bringing innovative technological solutions to plastics moulding industry in a manner that will set new standards of quality and service. We, in our humble way, will help reduce carbon footprint that our industry leaves behind. This will lead to more profit for our customers and have lasting impact on our planet.

Jayesh Modi Managing Director Ultra Cool 3D

Confidential, Patent Pending www.ultracool3d.com

Š Ultra Cool 3D 2011


Good cooling is not optional‌

Jayesh Modi Managing Director Ultra Cool 3D Confidentiality Note: Intellectual property protection is sought for various stages of our products, they are protected under various patents in various stages of application. No part of this presentation or technologies described herein may be copied, reproduced without express written permission of its proprietors.

Confidential, Patent Pending www.ultracool3d.com

Š Ultra Cool 3D 2011


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