Capability of multi-material powder bed fusion: Design, manufacturing, and validation of a smart injection molding tool

Powder Bed Fusion of metals using a Laser Beam (PBF-LB/M) offers unique possibilities to manufacture functionally graded materials composed of different alloys, enabling the creation of multi-material parts with material properties tailored to specific local requirements. In injection molding, optimized heat transfer and temperature control are key to the quality and productivity of the process. Combining a material with excellent thermal conductivity with a material with mechanical strength can be beneficial to improve the injection molding process. This work investigated the merits of an optimized copper structure in a multi-material injection molding tool while measuring its performance with integrated sensors. The sensor data were compared to data from a mono-material reference part. By incorporating a specifically designed copper geometry optimized for heat dissipation without compromising the stiffness of the tool, a reduction of the cycle time by 19% was achieved.