Additively Manufactured Cap Core with Precise Post-Processing

Additive manufacturing in toolmaking is often associated with prototypes or special solutions. However, it is increasingly proving that additively manufactured functional components can offer real advantages in production tools, especially where conventional cooling and flow channel designs reach their limits. A recent project at Faust Kunststoffwerk illustrates this potential using a newly developed cap core.

The objective was to stabilize mold filling, reduce material overpacking in the cavity area, widen the process window, and sustainably improve part quality. The core blank was additively manufactured from Printium 13 by Addition and subsequently precision-machined on all functional and sealing surfaces. Flow and thermal design were carried out by the engineering office Juri Müller.

The key factor is the internal geometry. Optimized cooling and flow channels enabled targeted control of pressure and temperature within the core area. Validation under production conditions showed a volumetric switchover point approximately 1.5 cm3 later, significantly reduced material overpacking, and lower mechanical tool stress. The process remained stable over 1.5 hours of production, 500 bar holding pressure proved sufficient, and the surface structure was more uniform.

The cavity is filled in a more controlled manner, resulting in a more robust process window and improved reproducibility. Additive manufacturing is therefore not an end in itself, but valuable where it enables geometries that are difficult to realize conventionally. For series production, this means lower process sensitivity, reduced scrap rates, and more stable manufacturing conditions.