Linear Motor Drive Precision Metal 3D Printer OPM Series · injection molding for...

MR30Manufacturing Cell System for eV-LINE OPM molds

apan made products

OPM SeriesLinear Motor Drive Precision Metal 3D Printer

Plus

http://ww

w.sodick.co.jp

ew ERA of the Plastic Molding Revolution

The revolutionary performance of Sodick’s OPM Series of precision

metal 3D printers enables manufacturing of molds (OPM molds)

with built-in three-dimensional cooling channels, fundamentally

changing how molds for plastic products are created.

The OPM Series lineup has been expanded by adding model OPM350L to the

previously available OPM250L model. OPM350L supports larger milling sizes,

and has been designed for faster milling. It has a new parallel mode function,

http://www.sodick.co.jp/product/tool/metal_3d_printer/catalogue/opm350l.html

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of the Plastic Molding Revolutionextended continuous operation function, in-process compensation function, and CNC unit. The OPM Series is creating a

new era in the manufacture of molds for plastic products. Using the OPM Series with the new MR30 manufacturing cell

system for eV-LINE OPM molds enables a comprehensive range of outstanding labor-saving benefits. These benefits include

maximizing the capabilities of molds with built-in three-dimensional cooling channels, improving productivity for molded

products designed for small-lot/high-variety production molding, shortening lead times, and greatly reducing costs.

Reaffirming our founders’ commitment to "Creating What We Cannot Find in the World," the Sodick Group is providing the

latest all-in-one solutions by drawing on proprietary elemental technologies for all production processes.

OPM Series MR30Linear Motor Drive Precision Metal 3D Printer Manufacturing Cell System for eV-LINE OPM Molds

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T he OPM Series models are fully automated metal 3D printers that attain a melting ratio of

99.9%. Metallic powder is spread uniformly (re-coating process), melted/solidified by a series

of ten laser emissions, and then subjected to a precision cutting process with high-speed

milling. These operations are repeated to create a 3D printed (layered) workpiece. The laser

oscillator that the OPM Series models use to melt/solidify the metallic powder is a fiber laser with a 500 W

output. The main spindle has a 45,000 rpm spindle that synergizes with Sodick’s original linear motor to

provide high-speed, high-precision metal 3D printing. An automatic tool changer (ATC) and automatic

tool length measuring device are installed to allow continuous automated operation over a long period

of time.

High Speed Metal 3D Printingigh Quality and

7 hr 58 min

7 hr 58 min

Milling speed improvement ◎Parallel mode 2.5 times faster

Cutting speed improvement

◎Less frequent shifting◎In-process compensation

reduces cutting allowance1.5 times faster

0 10 20 30 40 50 60 70 80(Time)

7 hr 58 min 39 hr 14 min




41% reduction

34% reduction

19% reduction

Milling time (per workpiece) Cutting time (per workpiece) *Total milling time consists of the milling time and cutting time, and does not include re-coating or tool replacement time.

Total milling time: 47 hr 12 min ▼Total milling time: 47 hr 12 min ▼



Total milling time: 79 hr 49 min ▼Total milling time: 79 hr 49 min ▼Quality

Quality

3 workpieces in parallel

3 workpieces in parallel

New shifting process

In-process compensation

Ten-layer shifting process



Ink tank mold coreWorkpiece Three workpieces in parallel × 2 Enlargement of one workpiece

Overall speed: 1.7 times faster

Larger Milling Size

Melting Ratio99.9%

Milling Speed Improvement

OPM350L has maximum milling dimensions of 350 × 350 × 350 mm (W × D × H), and

a maximum loading weight of 300 kg. It can print large workpieces with 2.7 times

greater volume and 3 times greater weight than OPM250L. A retractable footboard

and large aperture are provided as standard features, enabling the same ease of

operation as OPM250L.

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High Speed Metal 3D Printing

Parallel ModeFunction

Continuous Automated Operation for Extended Periods

In-processCompensation

MRS unit (option, shown on right)

The OPM Series comes with a parallel mode function,

enabling simultaneous milling of multiple locations

by controlling a single laser at high speed. A major

improvement in fume collection capability also

enables high-speed milling while maintaining high

quality. Cavities and cores milled in the parallel

mode can be created with built-in three-dimensional

cooling channels, effective for high-cycle molding.

Sodick has developed an optional MRS (Material

Recovery System) unit to enable fully-automated

metal 3D milling of larger workpieces. Excess material

ejected during the re-coating process is automatically

suctioned up and separated into cutting chips and

powder. Screened material powder is automatically

transferred to the machine, so the material powder

is circulated endlessly and thus making long-term

continuous automated operation possible.

The newly-developed in-process compensation

function periodically measures and compensates the

relative positions of the laser axis and milling axis while

milling. It minimizes the cutting allowance, and reduces

the milling time and cutting time. It also optimizes the

amount of metallic powder used for milling, effective

for saving energy and enabling greener manufacturing

and longer maintenance cycles.

No cutting remnants

OPM350LLinear Motor Drive Precision Metal 3D Printer

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Sodick’s manufacturing cell system for eV-LINE OPM molds was developed to maximize the

performance of molds (OPM molds) with built-in three-dimensional cooling channels created

by OPM Series precision metal 3D printers. The OPM mold is incorporated into a cassette,

greatly reducing mold replacement time. The system also includes all the functions needed for

molding, creating an equipment environment made up of compact cell units.

All-in-one Structure

Two Temperature Control Circuits

Sodick’s MR30 manufacturing cell system has an all-in-one structure

consisting of an eV-LINE injection molding unit combined with all the

peripheral equipment needed for injection molding. It has a compact

design and low height, and saves space and energy. After the resin

pellets (raw material) have been supplied to the tank, all processes (resin

preheating, mold temperature control, injection molding, and product

removal) can be done fully automatically. All the peripheral equipment

settings can be made from the MR30 operation panel, greatly improving

work efficiency.

MR30 comes with two temperature control circuits as a

standard feature. They enable maximum use of the local

cooling circuits created by the three-dimensional cooling

channels built into OPM molds, minimizing cooling time. They

are effective for high-speed injection molding of ultra-thin

products or precision molding of miniature products.

Auto selector(option)

Dryer silo

Drying filter

Granulator

Temperature controllers (2)

Two-stage drying conveyor (option)

Injection/Plasticizing unit

Temperature control circuit (1)

Temperature control circuit (2)

Flow of resin

Production in Great Varietieshe Production Cell System for Small-volume

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Cassette MoldThe cassette mold can be used to support miniaturized/precision

injection molding for small-lot/high-variety production. Inserting the

OPM mold into the cassette mold is the only setup work needed, enabling

optimized waste-free production matched to the production schedule.

MR30Manufacturing Cell System for eV-LINE OPM Molds

Cassette mold

Cassette mold replacement (illustrative example)

Cassette mold (fixed side)

1

23

4

5

6

1 Base mold

2 Cassette

3 Cassette core

4 Cassette cavit y

5 Molding machine noz zle

6 Valve gate

Production in Great Varietieshe Production Cell System for Small-volume

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OPM Series MR30Plus

Example OPM mold with built-in three-dimensional cooling channel: Waterproof connector mold

Waterproof connector flow analysis

The divided components of conventional molds can now be produced as one-piece units. Cooling channel positioning can also be optimized in ways not possible with conventional equipment. These benefits optimize the molten resin material flow, while reducing cooling time and improving stability during mold release.

Production time: 109 hr 40 min*　　Milling time: 59 hr 10 min　　Cutting time: 50 hr 30 min　Size: 68 × 86 × 53 mm

Production time: 138 hr 53 min*　　Milling time: 67 hr 49 min　　Cutting time: 71 hr 4 min　Size: 68 × 86 × 45 mm

Production time: 51 hr 35 min*　　Milling time: 11 hr 33 min　　Cutting time: 40 hr 2 min　Size: 20.76 × 9.58 × 77.66 mm*Production time for 2 workpieces.

*Production time for OPM production only. *Production time for OPM production only.

Production time: 54 hr 29 min*　　Milling time: 11 hr 49 min　　Cutting time: 42 hr 40 min　Size: 25.00 × 44.51 × 43.56 mm

Fixed side (bottom mold)

Movable side (top mold)

A

A

B

D

D

E

EB

15% 40%

80%

20%

60% 100%

Precedent

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OPM mold component drawing

Major reductions in mold production lead time and molding cycle time

*Production time including post-processing

Conventional mold component drawing

Precedent

Reduces mold production lead time and total cost.

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Mold productiontime

Molding coolingtime

Number ofmold components

Moldingcycletime

Conventional mold

OPM mold Core196.75 hr

Core363.5 hr

Cavity281.5 hr

Cavity215.25 hr

18.0 → 7.5 (seconds)

Conventional mold

Required cooling time (seconds)OPM mold

25.5 → 15.0 (seconds)

Conventional mold

Molding cycle time (seconds)OPM mold

18 seconds

7.5 seconds

25.5 seconds

15.0 seconds

Conventional mold


Core363.5 hr

Cavity281.5 hr

Cavity215.25 hr

18.0 → 7.5 (seconds)

Conventional mold


25.5 → 15.0 (seconds)

Conventional mold


18 seconds

7.5 seconds

25.5 seconds

15.0 seconds

Conventional mold


Core363.5 hr

Cavity281.5 hr

Cavity215.25 hr

18.0 → 7.5 (seconds)

Conventional mold


25.5 → 15.0 (seconds)

Conventional mold


18 seconds

7.5 seconds

25.5 seconds

15.0 seconds

Major reduction in lead time

Number of mold components: Reduced from 30 to 9A one-piece mold can be produced instead of a divided mold.

Three-dimensional cooling channel placement not possible with conventional equipment enables stable mold cavity filling, and a major reduction in the cooling time needed before product ejection.

MR30 comes with two temperature control circuits as a standard feature. The optimum local temperature control made possible by these two sets of die temperature control linesenables high-quality high-cycle molding under ideal conditions.

OPM mold with built-in three-dimensional cooling channel Two temperature control circuits enable high-cycle molding

Part No. Quantity Time*

111 1 47.50

112 2 184.00

113 1 31.00

114 1 26.75

115 1 6.25

116 1 5.75

117 1 12.00

118 1 43.50

119 1 6.75

Core total 10 363.50


101 1 119.25

102 2 73.50

103 1 4.00

Core total 4 196.75


521 2 42.50

522 1 106.00

523 1 8.00

524 2 5.25

525 1 8.75

526 1 8.25

527 1 8.00

528 2 6.25

529 2 6.75

530 2 4.75

531 2 5.00

532 1 4.25

533 2 1.50

Cavity total 20 215.25


501 1 161.00

502 1 112.50

503 2 6.50

504 1 1.50

Cavity total 5 281.50

*Production time including post-processing

58% reduction 41% reduction

18% reduction 70% reductionfewer components

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Dimensions

(With optional MRS unit)

Layout

OPM350L Specifications

Max. object size (Width) × (Depth) × (Height) 350 × 350 × 350 mmX-axis travel 360 mmY-axis travel 360 mmU-axis travel 344 mm

Machining tank internal dimensions (Width) x (Depth)

390 × 390 mm

Spindle Z-axis travel 100 mmMax. workpiece loading weight 300 kg

Nitrogen supply capacity 90 NL/minMachine tool dimensions (With optional MRS unit)

2020 × 2485 × 2575 mm

Machine tool weight (excluding peripheral devices) 5800 kg

OPM ULTRA1 (Maraging Steel)OPM SUPER STAR (SUS420J2)

OPM Stainless 316OPM Stainless 630

Machine SpecificationsLaser type Yb fiber laser

Laser wavelength 1070 nmMax. laser output 500 W (1000 W specification optional)

Laser scanning Galvano method

Laser

Options

Metal Powder

Max. spindle rotation speed 6000 to 45000 min-1

Max. spindle torque 0.8 NmATC tool holders 20

Tool holder systemDual-contact shrink fir holder

HSK-E25

Spindle / Automatic Tool Changer

Control axes 6 axes (X, Y, Z, U, B, Spindle)Simultaneous control axes Max. 4 axesMinimum input command 0.1 μm

Minimum drive unit 0.031 μm

LN4RP NC Unit

*Metallic powder used with OPM350L. For details, contact the sales department.

* Only Sodick-specified metallic powder materials can be used.* Some metallic powder materials require the use of a Sodick-recommended base plate.* Use of the OPM Ultra 1 or OPM Stainless 316 metallic powder materials requires a work environment conforming to health and safety laws (in Japan, the Ordinance on Prevention of Hazards Due to Specified Chemical

Substances of the Safety and Health Law).

• MRS unit • 3-light signal tower • External transformer• 100 VAC outlet • Air dryer (primary side) • Air tank • Material-restricting bellows (rectangular type) • 3-phase input cable • Shrink fitting device (Heat Robo) • Base master• Point master • Set of pin cushion parts • Power sifter (unneeded when using MRS unit) • Sifter (unneeded when using MRS unit)

• Sifter tray lid set (unneeded when using MRS unit) • Laser eye protection• Filter replacement dust mask• Filter replacement dust mask filters • Tool cutter• Demagnetizer• Magnetic flux density meter• Vertical probe (for magnetic flux density meter)• Industrial vacuum cleaner (for metallic powder; unneeded when using MRS unit)

• Silent cleaner (for fume cleaning)• High-power cleaner (for floor cleaning)• Initial processing tool set• Laser inspection

• USB memory• Large container (for fume collector cleaning)• Fume collector electrode (spare)• Activated carbon (for replacement)• Sintered metallic element (spare)• Protective synthetic quartz glass (spare)• Slide seal A (spare)• Blade acute (spare)• Blade acute (ceramic)• Fume collector activated carbon catalyst• Three-in-one multi dry filter (standard on overseas models)

• OPM Series Dedicated CAM OS-FLASH

Unit: mm

29202020

450

2575

2125

2195

1880

800

1650

2485

1295

150

600

4530

2340

495

800

780

300

1055

345

545

200

1250

205

-122

145

25

230 670

10502340145

3780

-540

6002001070840100

Cooler Assembly

Input Power Supply3-Phase AC200/220VH=1020 mm

Nitrogen GasGenerator (4NTE-3.7S)

390

Vacuum CleanerJX-3030SK (200V)

Fume Collector (FM-3DPS)

-370

5607102302020300

40

Air inFrom 0.7MPcH=1285 mm

Machine Power Supply

3820MRS-Unit

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Dimensions

Mold mounting drawings

Layout

MR30 Specifications

Maximum clamping force 294 kNTie-bar interval 360 × 360 mm

Daylight (mold thickness + stroke) 625 mmMold thickness 455 mmEjector stroke 50 mm

Screw diameter 25 mmPlunger diameter 22 mm

Maximum injection pressure 180 MPaTheoretical injection volume 27 cm3

Maximum injection speed 150 mm/sPlasticizing capacity 15 kg/hr

Machine dimensions (L × W × H)

2653 × 1462 × 2250 mm

Machine weight 2000 kg

Mold Clamp Plasticizing/Injection Unit Machine Dimensions / Weight

Dehumidifyingdryer

Autoselector(Option)

Mold temperature controller(2 System, Water)

Runner shooter(Option)

Molded part removal robot

Mounting layout drawing

850

540

2000

998

1258

(Par

ting

surf

ace)

(Noz

zle

heig

ht)

1095

1381

250

2250

(407)40590

2500

2653

(652)

View AGranulator

Conveyer(Upper & Lower, Option)

A

Material tank(Option)

2095

63

95

95

9577

0 385

385

310

1225 80

(468

.7)

1461

.6(1

87.9

)

(211

8.2)

71.6

1300

90

900

400

110

110

370

160

183

320

650

650

340

174.

532

0

494.

5

2- 16 H8 ReamerDepth 20

2- 12 ReamerDepth 16 6-M12 Tap Depth 30

Operation side

Fixed platen

370

110

500

500

110

350

340

6-M12 Tap Depth 30

360

360

Operation side

Movable platen

525

519

05

625

192

170

40

50

70

125

85

85 118

59.3

58.74-M12 Tap Depth 18

Upper Mold thickness

Max. Mold open stroke

Open Daylight

Base Mold

Lower Mold thickness

Insulation board thickness for Lower Mold Unit stroke

Ejector stroke Eject start positionCassette Mold

Resin feedBolt hole for hopper

Insulation board thickness for Upper Mold

Operation side

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Printed in Japan

3-12-1, Nakamachidai, Tsuzuki-ku, Yokohama, Kanagawa224-8522 JapanTEL: 81-45-942-3111 FAX: 81-45-943-7880

●�The export of Sodick's products and its related technologies (including software applications) is regulated under Japan's Foreign Exchange and Foreign Trade Control Law. In addition, because some of these products may be subject to re-export controls under the Export Administration Regulations (EAR) of the United States; please contact Sodick before offering or exporting these products overseas.

●This catalogue contains a photographic image that has been generated from 3DCG.●Options may be included in the photos of this catalog.●��Due to ongoing research, specifications are subject to change without prior notice.●The contents of this catalog is current as of July, 2017.

http://www.sodick.jp

S2020801.2017.07<02>

http://ww

w.sodick.co.jp

OPM

Series MR30

apan made products

Linear Motor Drive Precision Metal 3D Printer OPM Series · injection molding for...

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