Abstract Additive manufacturing (AM) offers high-freedom in the design and processing of components with complex internal structures. In this work, a new injection mold with the self-supporting large cooling channel and tailored porous structures was designed to improve cooling efficiency and save AM build costs. The optimized internal supports suppressed the collapse and warpage of large channels, which improves the manufacturability and breaks the geometric constraints of laser powder bed fusion (LPBF). The formable diameter of self-supporting channels is significantly increased (≥20 mm). In comparison to the 8 mm normal-sized channel, the self-supporting 13 mm channel reduces the cooling time of more than 20%. Additionally, the porous diamond structure was designated in the assembly part of the mold to save the materials and build time. To tune the strength, a core-shell composite structure with solid shell surrounding inner porous structures is designed. The influence of the wall thickness on the mechanical property of the composite structure was explored, which guides the specific mold design. Finally, a mold with the above-mentioned novel design was successfully processed by LPBF, which substantiates the manufacturability of innovative design. This work also inspires other industrial applications of AM-processed components with improved performance and functionality.

中文翻译：

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新型随形冷却模具的设计与增材制造

摘要 增材制造 (AM) 为具有复杂内部结构的组件的设计和加工提供了高度自由。在这项工作中，设计了一种具有自支撑大冷却通道和定制多孔结构的新型注塑模具，以提高冷却效率并节省增材制造成本。优化的内部支撑抑制了大通道的坍塌和翘曲，提高了可制造性并打破了激光粉末床融合（LPBF）的几何约束。自支撑通道的可成型直径显着增加（≥20 mm）。与 8 mm 普通尺寸通道相比，自支撑 13 mm 通道将冷却时间缩短了 20% 以上。此外，在模具的组装部分指定了多孔金刚石结构，以节省材料和构建时间。为了调整强度，设计了一种核壳复合结构，其内部多孔结构具有实心壳。探讨了壁厚对复合结构力学性能的影响，指导具体的模具设计。最后，LPBF成功加工出具有上述新颖设计的模具，证实了创新设计的可制造性。这项工作还激发了具有改进性能和功能的 AM 处理组件的其他工业应用。LPBF成功加工了具有上述新颖设计的模具，证明了创新设计的可制造性。这项工作还激发了具有改进性能和功能的 AM 处理组件的其他工业应用。LPBF成功加工了具有上述新颖设计的模具，证明了创新设计的可制造性。这项工作还激发了具有改进性能和功能的 AM 处理组件的其他工业应用。