3D Printed CNC Stainless Steel Parts for Tools and Molds

Service Process for 3D Printed and CNC Stainless Steel Parts in the Field of Tools and Molds

In the field of tooling and mold manufacturing, the service process for 3D printed and CNC (Computer Numerical Control) stainless steel parts has its unique characteristics. This is because these applications have extremely high demands for precision, durability, and efficiency. Below is a detailed service process tailored to this specific application scenario.

The advantage of 3D printing in tooling and molds is the ability to create complex mold inserts or custom jigs with conformal cooling channels.

1. Design Optimization and Flow Simulation

(1) File Reception and Analysis: The client provides the 3D model, usually in STEP or STL format. The service provider first evaluates the printability of the part.

(2) Design Review and Optimization: For mold inserts, engineers focus on reviewing the design of the cooling channels. Using thermal simulation software (like Moldflow), they simulate the cooling effect to ensure the channel design efficiently and uniformly cools the mold, thereby shortening the molding cycle time. For jigs, they evaluate structural strength and potential for lightweighting.

(3) Quotation and Confirmation: A detailed quote is provided based on the optimized design, selected stainless steel material (such as 17-4 PH or Maraging Steel), and printing process.

2. Metal Additive Manufacturing (3D Printing)

(1) Printing Preparation: High-quality metal powder is prepared, and the 3D printer is calibrated.

(2) Layer-by-Layer Printing: Under the action of a laser or electron beam, the stainless steel powder is precisely melted and stacked layer by layer to form the part with its complex internal structure.

3. Post-Processing and Heat Treatment

(1) Support Removal: Physical or chemical methods are used to remove the support structures generated during printing.

(2) Heat Treatment: This is one of the most critical steps. The part requires Hot Isostatic Pressing (HIP) or vacuum heat treatment to eliminate internal porosity, refine the grain structure, and relieve stress. This significantly improves the part's density, hardness, and mechanical properties, enabling it to withstand the high pressures and temperatures in a mold's operating environment.

(3) Finishing: The external surfaces are CNC-milled or ground to achieve strict dimensional tolerances and surface roughness requirements.

4. Quality Control

(1) Dimensional Inspection: A Coordinate Measuring Machine (CMM) is used to check key dimensions and tolerances.

(2) Internal Structure Inspection: Industrial CT scans or other non-destructive testing techniques are used to ensure the internal cooling channels are unobstructed and free of internal defects.

(3) Performance Testing: Hardness tests and material analysis are performed to ensure the heat treatment has been effective and meets standards.

CNC machining in tooling and molds is primarily used to produce high-precision, large-sized, and high-surface-finish mold bodies, die-casting molds, or high-precision stamping molds.

1. Drawing Analysis and Programming

(1) Drawing Reception and Review: The client provides detailed 2D engineering drawings and a 3D model, including all dimensional, tolerance, and surface roughness requirements. The service provider conducts a comprehensive technical feasibility review.

(2) CAM Programming: An engineer uses CAM software to plan tool paths and select appropriate cutting tools and machining strategies to machine complex cavities and features with maximum efficiency and precision.

2. Precision Machining

(1) Roughing: A large-diameter tool is used to quickly remove the majority of the material, getting close to the final shape.

(2) Semi-Finishing: The tool diameter is progressively reduced to improve machining accuracy.

(3) Finishing: A small-diameter tool and high-speed milling are used to achieve the mirror-like or fine surface texture required for the mold, ensuring product quality.

3. Heat Treatment and Surface Hardening

(1) Heat Treatment: After machining, the mold undergoes heat treatment processes like quenching and tempering to achieve extremely high hardness and wear resistance.

(2) Surface Treatment: Depending on the mold's application, surface hardening treatments like chrome plating, nitriding, or PVD coating are applied to further improve its hardness, wear resistance, and release properties.

4. Quality Control

(1) CMM Measurement: All critical dimensions, shapes, and positional tolerances are measured with 100% inspection.

(2) Hardness Testing: A hardness tester is used to check the surface and core hardness of the part to ensure the heat treatment was effective.

(3) Surface Roughness Testing: A surface roughness gauge is used to ensure the surface finish meets the drawing requirements.

Common Materials in producing 3D Printed and CNC Stainless Steel Parts in the Field of Tools and Molds

3D Printed Stainless Steel Parts

For 3D printing, the material is chosen to enable complex geometries and is then processed to enhance its mechanical properties.

Materials: 17-4 PH, Maraging Steel

Corresponding Characteristics: Complex Geometries and Conformal Cooling Channels. These materials, in powder form, are ideal for additive manufacturing. They allow for the creation of intricate internal cooling channels that cannot be machined conventionally. This design freedom directly leads to more efficient heat dissipation in molds, significantly reducing cycle times.

Post-Processing Feature: Heat Treatment (HIP). After printing, these materials have some porosity and internal stress. A post-printing HIP process is crucial to achieve the required density and mechanical strength for demanding applications like molds and tooling.

Material: 316L Stainless Steel

Corresponding Characteristic: Corrosion Resistance. While not as hard as the other materials, 316L is used when the primary requirement is resistance to corrosion, particularly in harsh chemical environments. Its excellent printability also allows for the creation of complex shapes for fixtures and jigs where strength is secondary to resistance.

CNC Stainless Steel Parts

For CNC machining, the material is selected for its machinability and pre-existing properties, which are then refined through precise cutting and finishing.

Materials: 420, P20, H13 Tool Steel

Corresponding Characteristic: High Precision and Tight Tolerances. These materials are specifically chosen for their stability and machinability. They can be cut with extreme accuracy, allowing for the creation of perfectly fitting mold halves and intricate features with micron-level precision.

Post-Processing Feature: Heat Treatment and Surface Hardening. These materials are often heat-treated after machining (like 420 and H13) or come pre-hardened (like P20). This processing step corresponds directly to the need for very high hardness and wear resistance in tools and molds, which are subjected to constant friction and stress.

Materials: 304, 316L Stainless Steel

Corresponding Characteristic: Excellent Surface Finish. These materials are highly machinable and can be cut to achieve a smooth, high-quality surface finish. This characteristic is essential for creating polished mold cavities, hygienic components for food and medical industries, or aesthetically pleasing tooling parts. The use of these materials aligns with applications where appearance and cleanliness are as important as dimensional accuracy.

Why choose us to produce 3D Printed and CNC Stainless Steel Parts in the Field of Tools and Molds

1. Comprehensive Manufacturing Capabilities

We offers more than just a single service. By seamlessly integrating both 3D printing and CNC machining, they provide a complete, one-stop solution. This allows them to combine the strengths of both technologies—using 3D printing for complex features like conformal cooling channels and CNC for high-precision, large-scale components. This saves clients the time and effort of coordinating between multiple vendors.

2. Specialized Material and Process Expertise

Tooling and molds demand exceptional material performance. We provides deep technical consultation, acting as a material selection expert. They understand how different stainless steels (like 17-4 PH, 420) perform under various manufacturing processes. They can recommend the optimal material to balance performance, cost, and production time for specific applications (e.g., injection molding, die casting).

3. High-Quality Standards and Strict Quality Control

In this industry, even a small error can be costly. We ensures high quality with precision equipment and a rigorous quality control process. Beyond standard dimensional checks (using CMMs), they may use advanced techniques like industrial CT scans to verify the integrity of internal structures in 3D printed parts. This commitment to quality is crucial for high-value projects.

4. Extensive Industry Experience

With a rich portfolio of successful projects across demanding industries like automotive, aerospace, and medical. Waltay has proven its ability to handle complex challenges. Their extensive experience means they can anticipate and solve technical problems, offering practical solutions that significantly reduce project development time.

Waltay is specializing in custom CNC machined parts for over 15 years. We are good at making high precision metal and plastic components. We also provide one stop service such as part design, prototypes, mold making, plastic injection and part assembling to better meet customers’ needs. Beside aluminum CNC machined parts, we also provide stainless steel, ABS, PC, PA,PP and POM CNC machined parts which can be widely used in cables, sensors, motors,connectors, etc.