Siegfried Hofmann 3D prints aluminum molds for particle foam

Siegfried Hofmann GmbH, a developer of multi-cavity molds, and GROB-WERKE GmbH & Co. KG, a developer of manufacturing systems and machine tools, have collaborated on the production of a 3D printed aluminum mold solution for particle foam.

The molds are corrosion-resistant, and lighter than their stainless-steel counterparts – allowing for optimum vapor deposition, venting, and homogeneous filling. They are faster and more flexible to manufacture – thanks to the use of metal 3D printing.

Thanks to GROB’s liquid metal printing process, it can take as little as a week from the start of the design to the first foaming in the mold – depending on the complexity of the project. Ideal for series parts with basic surface quality requirements, the lightweight molds are also the best solution for short-term prototype testing of materials, spraying, and evaporation.

“We are particularly proud of the rapid production of the additively manufactured aluminum foam molds,” said Stefan Hofmann, Managing Director of Siegfried Hofmann GmbH. “We only needed a third of the time to produce our demonstrator tool compared to its 3D printed steel counterpart.”

The molds perform optimally in combination with the BEAD.MACHINE particle foam molding machine from Hofmann. Up to 50 % porosity in the mold insert ensures maximum evaporation of the raw material – so even large parts can be produced seamlessly. At the same time, the high number of steam nozzles results in shorter cycle times due to faster heating and cooling processes.

Different mold inserts for one product can also easily be used with just one mold frame – saving costs and speeding up the production process.

The GROB-WERKE Metal Printing process, also known as Molten Metal Jetting, is characterized by high system flexibility, low component production costs, and high system reliability – meaning that the process can be easily integrated into any existing production setup.