A Revolution in Creating Moulds with Metal 3D Printers
Reducing Costs and Creating New Value
Various examples of building including ECU case moulds
MUTO handles everything from moulds for resin parts to moulding and assembly, and is now making moulds using metal 3D printers. By adjusting the moulding cycle, we aim to reduce costs and equipment for moulding machines.
In addition, they plan to combine this technology with other technologies to improve added value.
"Metal 3D printers will bring about a revolution in manufacturing," said Managing Director, Kenji Kumazawa.
MUTO handles everything from moulds to moulding, coating, and assembly of resin parts for automobiles and home appliances, including ECU cases.
With factories in Vietnam, China, and Thailand, the group as a whole has an annual production capacity of 150 moulds and more than 520 moulding machines.
MUTO consistently handles various resin parts, from moulds to moulding, coatng, and assembly.
Even with such a large supply capacity, the company faces the challenge of further improving its cost competitiveness. “With the electrification of automobiles, competition is intensifying, and some manufacturers that handle other parts such as engines are entering the resin business,” said Kumazawa.
In order to increase cost competitiveness, they decided to make moulds using metal 3D printers. "The only way to reduce the moulding cost is to save on manpower and improve the cooling effect of the mould." For that reason, it was determined that it was essential to create moulds using metal 3D printers that freely forms water pipes and achieves a high cooling effect. Two years ago, the company installed Sodick's LPM325.
Sodick's metal 3D printer "LPM325" was installed to improve cost competitiveness
The goal is to "reduce costs by at least 20%".
By shortening the cooling time, a number close to the goal is possible. Currently, the company is building eight moulds such as moulds for ECU cases, and is in the process of accumulating various building conditions and know-how.
For example, setting the stacking height of one layer to ensure the shape and accuracy required by the company.
In addition, the company is in the process of determining the hole diameter and distance to the surface for optimum cooling effect.
Mould with cooling piping inside (ECU case) made using a metal 3D printer
Of course, there are challenges. One challenge is cost. The material used is SUS420J2 "SUPERSTAR 21" provided by Sodick, but "compared to the conventional method, it is about three times more expensive," says Managing Director, Kumazawa. Therefore, they have devised ways such as shortening the machining time from 14 days to 9 days.
Through these efforts, the goals for precision and cost are in sight. After that, Kumazawa says, "I want to verify the number of shots in mass production and expand the usage method."
Managing Director Kumazawa says that the metal 3D printer is "revolutionary" not only because of the improved moulding cycle. One way it is revolutionary is the ability to lighten the burden on equipment. "Simply increasing the cycle by 20% will require 20% fewer moulding machines, even if the same production volume is maintained."
It is also important to be able to create new value by combining various technologies. For example, "combining with heat & cool technology, eliminating welds, and improving surface accuracy will lead to paintless applications." In addition, the company wants to promote conversion to a hot runner (HR) system. Accurately cooling the hot parts of the HR system and increasing the use of HR "will lead to resin-less use". Through these efforts, MUTO can "provide new value by contributing to carbon neutrality".
Metal 3D printers lead to cost reductions and provide new value. Director Kumazawa states, "In the future, we would like to consider adopting this technology at our bases in each country," and intends to accelerate the manufacturing revolution with metal 3D printers.
Sodick electrical discharge machines lined up at the company's factory
Kenji Kumazawa, Managing Director
