Conformal Cooling Insert For Hot Stamping Die Cavities

Thermal & Hydraulic Parameters

Heat removal capacity: up to 8500 W at a coolant flow rate of 6 L/min and an inlet pressure of 5 bar.

Channel diameter: 3.5 mm with wall thickness between 0.8 and 1.2 mm, tested to a burst pressure of 25 bar.

Surface temperature uniformity maintained within ±5°C across the insert face during continuous cycling.

Material & Additive Manufacturing Process

Maraging steel 1.2709 powder is used in the DMLS 3D printing process. After printing, the insert undergoes solution annealing and aging to reach 52-54 HRC.

Internal channels are lightly abrasive-flow machined to achieve an Ra of 1.6–3.2 µm for minimal flow restriction.

CT scanning validates channel integrity and 100% density, ensuring no leak paths.

Temperature Regulation Principle in Stamping

Coolant flowing directly behind the die cavity wall removes heat transferred from the hot blank (around 900°C) during forming and quenching.

By actively limiting temperature peaks, it prevents die surface softening and cracking, stabilizes martensitic transformation in the sheet metal, and enables a cycle time reduction of up to 15%. Quick-disconnect push-lock fittings allow integration with the press water manifold.