Additive Manufacturing Solution for Injection Molding

This case study details a manufacturing solution implemented by Fathom for a customer experiencing assembly issues due to warping of a part feature in injection molded components. The warping was attributed to the long cooling cycles required for HDPE materials, which have a high shrink rate and caused circular features to become unusable. Fathom's experts identified the cooling issue and designed a conformal cooling system using Direct Metal Laser Sintering (DMLS) to create a new core insert. This innovative approach allowed for the incorporation of cooling channels in previously inaccessible areas, enhancing the cooling process. As a result, the customer achieved a 13% reduction in cycle time, saving 168 production hours on a run of 100,000 pieces. The improvements led to decreased operational costs, reduced wear on machinery, and enhanced product quality through increased dimensional accuracy. The case study illustrates Fathom's comprehensive capabilities in addressing manufacturing challenges.