Cycle Time Optimization

Based on our experience in high-pressure die casting, we know that even small improvements in cycle time can lead to significant gains in throughput and cost efficiency. In this case, we applied our expertise in thermal management and conformal cooling to reduce cycle time—without compromising part quality or process stability.

Results at a Glance

CYCLE TIME:

-5.48% (from 73 sec to 69 sec)

A Case-Based Approach

To enable faster cycle times, we redesigned the cooling system in the distributor and produced it with Additive Manufacturing (AM).

The conformal cooling layout allowed for more efficient heat dissipation in critical areas, enabling a 4-second reduction per cycle.

This translated into higher productivity and longer tool lifetime, thanks to reduced thermal stresses.

The Scenario

Conventional Process

Before the optimization, the process had a cycle time of 73 seconds. A total of 450,000 parts were produced.

The Performance

Conformal Cooling

The integration of conformal cooling technology in the distributor brought measurable improvements to the production process. By optimizing the thermal management and reducing interventions, the updated setup enhanced efficiency and profitability across multiple dimensions.

The scrap rate dropped to 3,9%, while cycle time was reduced by 4 seconds, allowing for faster throughput without compromising quality, and cleaning time per shift was cut to just 7 minutes.

By combining Additive Manufacturing with application-specific engineering, we helped the customer reduce cycle time and maximize output, while maintaining full process reliability.