ultracool3d-corporate-r11

Jayesh Modi

Managing Director, Ultra Cool 3D

[email protected]

+61 410 095 160

REDUCING CYCLE TIMES

AND IMPROVING PART QUALITY

mailto:[email protected]

Confidential, Patent Pending © Ultra Cool 3D 2011 www.ultracool3d.com

• Most plant engineers have spent endless hours in trying to control Warpage.

• Many hours were spent on meeting tolerances of part.

• Even after all efforts, residual stress in parts made part unacceptable in field service,

can you afford brand damage?

Warpage, Long Cycle Times, Tolerances

http://www.ultracool3d.com/


Cas

e 1

Simplified cooling causing heat build-up

50% cycle time reduction target

• Very high temperature gradient

• 40 sec cycle time

• High warpage

Development Possibilities – Automotive Siren



Cas

e 2

Simplified cooling causing heat build-up

40% cycle time reduction target

• Very high temperature gradient

• 50 sec cycle time

• High warpage

Development Possibilities – Automotive ECU



Limitation of cooling in

tool shows up instantly

on a simple IR image.

Far more effective than

single point pyrometers

used.

Cas

e 3

Development Possibilities - Mirror



Excessive temperature variation, long

cycle time, warpage.

Cas

e 4

Development Possibilities – Air Intake Manifold



Husky Analysis, 12.6 sec. Cycle time

Rigid Packaging Benchmarking Study C

ase

5

(Source: Husky Seminar Notes)



Blocked cooling channel, product quality issues.

Rigid Packaging Tool Diagnostic C

ase

6



Ultra Cool 3D’s rigorous design methodology with proprietary algorithm

aims to deliver a remarkable thermal response.

UltraCool3D will help you:

- Control Warpage

- Control Weld lines

- Control gas blow out in MuCell

- Reduce Cycle time

- Unlock “Hidden Capacity” Cost

Quality

Realise Those Profits



• 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

Solution UltraCool3D



Finished poppet

3D cooling on poppet head.

Very small temperature differential over entire part, leading to

great warpage control and shortest possible cycle time.

Project- Lid



3D Conformal Cooling

Conventional cooling

30% Cycle time reduction target.

Project- Bezel



Project- “Rib Cage” 3D Cooling



2o C temperature differential over entire part !

Flatness achieved 40 Micron !!

Project- Ultra Precision Moulding



In addition to part thickness….

Distance- cooling channel maximum distance to mold wall.

Distance- cooling channel minimum distance to mold wall.

Distance- cooling channel pitch distance.

What Affects My Cycle Times?



54 % extra cycle time

Profit lost ! 23

o C differential

Warpage !

Why Does It Matter?



Process drift (100+ shots to stabilise)

Poor Quality !

23o C differential-

Warpage

Reversal from

-7 o C to + 23

o C Un-

stable tool

-7 o C

+ 23o C

Why Does It Matter?



o Based on algorithm developed at MIT.

o Design for six different criteria- uniform cooling of part, part eject temperatures,

part mid plane temperature, mold deflection, 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.

Proprietary Software



Proprietary Software At Your Service



• Our technology is developed in Australia and analysis carried out

• at CSIRO and Dept. of Defense facilities by use of advanced scanning electron

microscopes.

Quality Built-In



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

Mission Statement



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.

Good Cooling is Not Optional…


ultracool3d-corporate-r11

Documents

d cooling confidential

quality confidential

tolerances confidential

profits confidential

cycle time reduction

project lid confidential

project bezel confidential

shortest possible cycle