Mould with an optimies topology

The Starting Point – Conventional mould for plastic injection moulding
The existing mould, made of mould inserts, plates, clamping plates, and standard parts, measures 125 x 125 x 130 mm and weighs about 60 kg. The project aimed to optimize the injection moulding process by reducing cycle time and simplifying the assembly complexity. Using additive manufacturing, the mould was redesigned and its topology optimized according to loads and requirements. The result: a smaller, lighter mould with integrated conformal cooling.

The Challenge – Maintaining functionality
During topology optimization, critical functional surfaces like mold half alignment, ejector system position, and machine interface had to be preserved. The design also accounted for subsequent clamping for CNC post-processing. Distortion during metal 3D printing posed another challenge. Optimal part orientation, support design, and process simulations helped detect distortion early and avoid scrap. The “first time right” principle is key here.

The Approach – End-to-end process with Siemens NX
From redesign, material selection, and cooling integration to FEM and cooling simulations, data prep, print simulation, metal 3D printing, finishing, and CNC machining, the process was digitally mapped and efficiently executed. Quality control was optical and tactile. The mould was then successfully deployed in production.

The Result – A step toward the future of mould making
The new 3D-printed mould features smaller dimensions and nearly 50% less mass. Reduced weight simplifies installation and lowers machine clamping forces. Thanks to conformal cooling, cycle times decreased by 30% while maintaining part quality.