日本技術情報センター Company Profile

Copper, which has a high reflectivity for lasers and quickly dissipates the thermal energy from laser irradiation, was difficult to shape using metal 3D printers. However, recently developed high-performance and high-functionality metal 3D printers, along with pure copper and copper alloy powders that have a high absorption rate and excellent 3D moldability, have been introduced to the market, leading to rapid practical application in advanced companies. Metal 3D printers can now create complex shapes in a single build, lattice/porous structures, and hybrid designs, which were previously impossible. This enables the creation of innovative parts, rapid development and prototyping of components, significant reductions in the number of parts, improved quality, lightweight and compact designs, and cost reductions. The adoption and utilization of these technologies are becoming more active in applications such as heating coils, heat sinks, heat exchangers, motor coils, and electronic and electrical devices. In this seminar, we will discuss the latest trends in pure copper and copper alloy powders suitable for 3D additive manufacturing, developed by Fukuda Metal Foil Powder Industry, which enhance laser absorption. We will also present case studies on the layered molding of pure copper and copper alloys, as well as examples from leading users such as TK Engineering, ODEC, and Fasotec, who are utilizing metal 3D printers to manufacture low-cost, high-quality copper parts in a short time. The seminar will provide an easy-to-understand explanation of innovative molding technologies and cases that are not found in traditional or other companies, including success and failure stories, aimed at beginners.

Metal 3D printers enable the creation of complex shapes that are difficult to achieve with traditional processing methods and technologies, including integrated manufacturing of complex shapes, 3D freeform pipe manufacturing, lattice and porous structure manufacturing, and hybrid structure manufacturing. This leads to the creation of innovative die-casting molds, cost reduction and quality improvement, short-term development, prototyping, and manufacturing, significant reduction in the number of parts, lightweighting, reduction in manufacturing processes and workforce, and extended mold lifespan. In this seminar, we will first explain the latest examples of short-term mold manufacturing technology using wire and laser metal 3D printers capable of multi-layer manufacturing of dissimilar metals, additive manufacturing on existing parts, and large-scale manufacturing, as well as the reduction of lead time for mold prototyping, extending mold lifespan, and repairing damaged molds. After that, advanced users J.3D and Casttec, who boast top-level technology in Japan for die-casting mold manufacturing using metal 3D printers, will provide easy-to-understand explanations for beginners about specific molding technologies and examples of high-functionality and high-quality die-casting molds, core pins, and inserts for die-casting molds made using EOS-manufactured metal 3D printers, which have suppressed and prevented various defects and troubles associated with traditional methods. Additionally, we will introduce the recently popular topic of giga-casting, which has garnered attention in the United States and China.

In this seminar, we will briefly explain various methods and technologies for creating plastic molds using metal 3D printers, key points and considerations in production, and examples of fabrication. Following that, advanced users utilizing metal 3D printers from EOS, 3D Systems, Sodick, and Matsuura Machinery will discuss cutting-edge mold manufacturing technologies and cases, as well as the factors behind failures and secrets to success. First, we will explain examples of low-cost, high-quality manufacturing technologies achieved through complex shapes and integrated fabrication, hybrid fabrication, and 3D cooling water pipe fabrication using EOS metal 3D printers at J-3D, which lead to shortened lead times, weight reduction, and cost savings. Next, we will discuss ODEC's achievements in dramatically reducing lead times and costs in mold renewal by producing complex molds for resin molding with metal 3D printers, along with the latest fabrication examples and technologies for designing internal structures (3D water pipes), flow, and temperature simulations. Finally, we will provide specific explanations of the industry-leading mold manufacturing capabilities of Sanko Gosei using metal 3D printers, including remarkable reductions in mold cooling times through 3D cooling water pipe fabrication, and how porous fabrication effectively mitigates issues such as short shots and gas burn, as well as examples of reduced injection times.