THE CUSTOMER
Slovenian die caster
HTS SOLUTION
iTherm® conformally cooled die insert
THE CHALLENGE
Hot spot elimination
OUTCOME
13% cycle time reduction
Case study overview
Our Slovenia based customer, specializes in the development and production of advanced solutions for OEM to TIER1 and TIER2 suppliers.
They faced significant issues with insert overheating. During the solidification phase, insert temperatures exceeded 550°C, and they were around 340°C before spraying. This overheating caused die soldering, prolonged solidification, and increased cycle times.
To cool the inserts, an intensive and lengthy spraying phase was required. The customer even switched to high-conductive tool steel inserts, which reduced temperatures, but the need for intensive spraying persisted. This excessive spraying phase shortened die life, resulting in frequent maintenance and replacements. Despite various interventions, the customer faced ongoing inefficiencies and rising operational costs.
Thermal performance comparison
Temperature before spraying
Temperature after spraying
Thermal performance comparison
Cycle analysis
* Both screen shots are taken in the same time frame during solidification, when the iTherm® system already reaches full solidification while conventional design is still in partially liquid state. **For this part alone.
Results
The reduction in die insert temperature effectively solved the aluminum sticking problem. As a result, the customer was able to reduce cycle times and increase productivity significantly.
Return on investment
As a part of HTS standard procedure, the ROI for the insert was estimated.
Efficiency Comparison
The iTherm® insert reduces cycle time by 13% compared to conventional inserts. Completing 100,000 shots takes 69 days with a conventional insert, while the iTherm® insert completes the same number of shots in just 60 days.
Cost Savings
With a machine hourly rate of €100, using the iTherm® insert results in a cost savings of €0.22 per shot.
*The machine hourly rate is estimated at 100€ | ** The price of the conventional distributor is estimated | *** Calculated with 14h casting per day
Break-Even Analysis
To offset the initial price difference between the iTherm® insert and the conventional insert, 14,169 shots are required. This break-even point is reached in 15 days.
