PROGRESS BEYOND STATE-OF-THE-ART.
Improved end-product: SLM technology enables the construction a completely new generation of innovative tools with multiple cavities (mould inserts) that is only possible with SLM technology. This offers many advantages for the manufacturing processes of moulded foam parts, including new design methods and systems. Further, in using SLM Tools moulds, EPP components have improved surface quality over traditional techniques to offer an excellent finished product.
Production cost saving: When used for EPP mould production, SLM Tools has the following effects:
• Reduction of energy consumption by 70%
• Increase plant output by 100%
• Reduction of tool weight by almost 50%
• Tool lifetime increased by 500%
• Reduction of cooling water consumption by almost 90%
• Reduction of the cycle time by 67%
• Redesigned surfaces and absolute design freedom
• Tool cost per part 4x cheaper (from 7.5c down to 1.8c)
EXPECTED RESULTS.
Our principle objective is to develop SLM Tools technology to TRL9 and prove that SLM Tools can 1) produce complex structures for mass-production cost-effectively in large series, increasing EPP production by 100%; and 2) reduce energy usage by 70% and water usage by <90% (and the associated CO2). In all, we target to prove costs are reduced by 16%. To achieve and evidence this, during the intended Phase 2 project, we plan to action the following technical and commercial objectives:
• Scaling from TRL6 to an efficient production environment validated by extensive testing.
• Automation of design processes; extension of toolmaking to larger or more complex tools.
• Productivity increase of SLM technology; process-reliable conception for SLM tools.
• Production-ready design and production processes for SLM mould foam production tools.
• Attend commercialisation events to demonstrate results and increase market awareness.
• Protect IP in the target market locations, mainly with patents.
• Scale-up for SLM Tools market entry.
As we progress SLM Tools to TRL9, we will increase marketing activity to generate our first sales in 2022.
IMPACTS.
Beyond the economic benefits that cheaper and increased complexity moulding will bring to Europe, there are also significant water, materials, energy and CO2 savings. Should SLM Tools become industry standard and replace the entire inventory of EPP and EPS moulded foam machines, the theoretical savings volumes in mould manufacturing are estimated at:
• 555 million m3 water
• 15,048 million kWh energy
• 3,036 million m3 CO2
Further to this, in production of EPP, further savings can be realised of:
• 25,080 tons material saved and their related manufacturing impacts
• 3,080m kWh energy
• 154 million m3 CO2
