HERMLE Maschinenbau GmbH

Multi-material pre-chamber bushing for plastic injection molding, manufactured from a total of four different materials. Additionally, a graded transition zone was created between the base and the tool steel to mitigate differences in the coefficients of thermal expansion. Two different tool steels were used in the upper part of the component to create corrosion resistant and wear resistant material behavior where it is needed. The lower part of the component consists of a copper based alloy as a compromise between strength and thermal conduytivity. Additionally there are pure copper segments in the steel to enhance thermal conductivity from the upper part to the lower part of the component.

With Cold Spray Additive Manufacturing the component could be manufactured with ideal material properties exactly where they are needed instead of a overall compromise.

Material: Semi-finished CuNi2Si / Additively manufactured 1.2083, 1.2379, and pure copper

Manufacturing process: Cold Spray (HERMLE MPA) and subsequent machining

With the HERMLE MPA technology an Invar cooling frame with integrated copper heat pipes for use in a die-bonding device was manufactured. The copper heatpipes were placed into a premilled Invar36 part and afterwards pure copper and Invar36 were sprayed onto the part to integrate the heatpipes into the part. Because of the cold spray process there is a really good material bond and therefore an ideal thermal conduction between the heatpipes and the rest of the part.
The aim of this part was to find a substitute for a water cooling and eliminate the risk of leakage.

Material: Semi-finished Invar36/ Additively manufactured Invar36 and pure copper

Manufacturing process: Cold Spray (HERMLE MPA) and subsequent machining

Heat exchanger plate with an internal channel system for a calorimeter. Originally manufactured by brazing. However, brazing presented the issue of potential residual leaks between the channels, leading to inaccuracies in subsequent measurements.
With the HERMLE MPA technology, an internal channel system was created thanks to a sprayable water-soluable filler material, which can be washed out after the manufacturing process.

Material: Semi-finished CuCr1Zr / Additively manufactured CuCr1Zr

Manufacturing process: Cold Spray (HERMLE MPA) and subsequent machining

Material: Semi-finished H11 / Additively manufactured H11 (with integrated heating wires and thermocouples)

Manufacturing process: Cold Spray (HERMLE MPA) and subsequent machining