The principles of die casting are similar to injection molding in that molten metal is forced under pressure into a mold where it takes the shape of the final part. The part must then cool and solidify before it can be released from the mold.
Obviously, metals have a much higher melting point than plastics, so this extra heat combined with pressure can damage the mold through cracking and corrosion. When you scale up to casting large parts, the time required for cooling increases significantly.
To speed up the process, cooling channels can be added to the mold, where the coolant carries heat away, resulting in faster cycle times and higher productivity. 3D printing allows curved channels to be added to molds or molds to more closely match the surface of the tool and the shape of the part, allowing heat to escape faster than traditional cooling channels. Not only does it reduce cycle time, but it also improves part quality, and material properties, and reduces costs. The strategy of drastically reducing the number of body parts manufactured has resulted in a dramatic reduction in the complexity of the body line and the capital required to build the line.
It also brings a weight advantage to the vehicle itself, which in turn can improve efficiency.
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