A Doncaster business has used its innovative 3D metal printing solution to create mould tools reducing energy consumption and water requirements for a product that will be used worldwide. Precision engineering experts, Agemaspark, invested in 3D metal printing technology which, when combined with its unique conformal cooling technology in the manufacture of plastic caps and closures, is reducing cycle times by 20 percent.

Working with long term client Silgan Closures, Agemaspark used 3D metal printing technology to create mould tools for plastic injection moulded caps and closures delivering a 20 percent reduction in cycle time as well as reducing the energy consumption for the same output. With options for reducing cooling water requirements from tens of thousands of litres used in any 24 hours to just 20>50 litres. Electrical Stamping Parts

Agemaspark has worked with Silgan Closures for more than 18 years on conventional moulding tooling for their plastic injection moulding components. Following an EU directive to change to tethered caps for drinks cartons the partners discussed making new mould tools with a view to improving the manufacturing process. Paul Stockhill, managing director of Agemaspark said: “Our solution found a way to save energy, using our conformal cooling technology, we can reduce cycle time by up to two seconds.”

Conformal cooling is the process of using coolant channels in plastic injection mould tools which closely follow, or conform, to the shape of the part being moulded. The process consumes less raw material and energy during manufacturer as the tool can be made smaller.

The companies ran a number of trials of the moulds and have now delivered a product that enables these drinks caps to be manufactured in a more environmentally friendly way.

Silgan Closures provide closures in more than 50 countries across the globe. Their closures are used on liquid cartons, and plastic sports drinks bottles, the closures need to be suitable for hot or cold drinks, be tamper-proof and resealable.

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Stockhill added: “We are extremely proud to have created the mould tool design concepts and tooling designs for Silgan Closures. It is fantastic to be working with them in partnership on their wide range of caps and closures.”

The company is continuing to test moulds and designs and is now working on two new prototype tools for the company converting existing conventional tools to conformal cooling tools. “Our techniques can be used to help industries from oil and gas to aerospace and from medical and clinical to tooling. We are looking forward to using this application to help more sectors improve their environmental foot print”, Stockhill adds.

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