Towards Bi-Metallic Injection Molds by Directed Energy Deposition

Abstract The throughput of the injection molding process is restricted by the cooling time of each cycle which accounts for three-fourths of the cycle time. Manufacturing molds out of copper or copper alloys can reduce the cooling time because of their high thermal conductivity, but mold life is reduced because copper has much lower hardness and strength than traditional mold materials such as steels. By layering steel onto copper using directed energy deposition, the advantages of both materials can be exploited to reduce cycle time while maintaining mold durability. In this study, 17-4 PH stainless steel was deposited onto a copper substrate to demonstrate the potential to create multi-material injection molds.