Unlocking Innovations in Tooling: A Conversation With Vilas Ravindra Dulipeta of AarKel Tool and Die

October 30, 2024 | Reading time: 5 min

 

In a captivating episode of the Additive Snack Podcast, host Fabian Alefeld interviews Vilas Ravindra Dulipeta, a key leader in the additive manufacturing (AM) sector at AarKel Tool and Die. Their discussion sheds light on the transformative role of AM in the tooling industry, showcasing how AarKel’s role as a major trendsetter.

Founded in 1977, AarKel has grown into a global powerhouse in tool and die manufacturing, with locations in Canada, Mexico, India, and the United States. Known for its expertise in plastic injection molds and die-casting applications, AarKel has been pushing the boundaries of innovation, particularly with their integration of AM technologies like the EOS M 400 metal 3D printer.

 

Vilas's Early Encounter with Additive Technology

Vilas's passion for mechanical engineering and the automotive industry was evident from a young age.

Growing up, his love for cars fueled his drive toward mechanical engineering, and his journey into AM began during his undergraduate years in India. He participated in the Society of Automotive Engineers (SAE) Formula Student racing, where he first encountered 3D printing technology.

From 2010 to 2012, Vilas worked with PLA filament printers as part of a rapid prototyping course, where he experienced firsthand how this technology could revolutionize the design and production of components. This early exposure set the foundation for his future endeavors.

After completing his bachelor’s degree, Vilas pursued a master’s in automotive engineering at the University of Windsor in Canada. It was during this time that he became part of AarKel Tool and Die, where he would later play a pivotal role in integrating AM into traditional tooling processes.

 

Additive Manufacturing at AarKel: A Game-Changer

AarKel’s journey into AM began about six years ago, driven by the company’s commitment to staying at the forefront of new technology. Initially focused on traditional tool and die manufacturing, AarKel began exploring metal 3D printing as a way to enhance its offerings. EOS, one of the world’s leading manufacturers of AM systems, introduced the M 280 and M 290 metal 3D printers around this time, and AarKel saw the potential to apply this technology to its die casting and injection molding processes.

The transition wasn’t without its challenges. As Vilas explains, early iterations of the EOS machines were not designed specifically for tooling or molding applications, which required AarKel to adapt the technology to fit into their existing processes. "We had to figure out the fixturing, machining, stock allowance, and heat treatment," Vilas noted, emphasizing the steep learning curve that came with adopting AM.

But AarKel persevered. By developing proprietary techniques, such as hybridization, it was able to integrate 3D printed inserts into traditional molds. The ability to combine AM with conventional CNC machining opened up new possibilities, allowing AarKel to enhance the tool performance while reducing costs and cycle times.

 

Revolutionizing Die Casting with 3D Printed Inserts

One of the most significant innovations AarKel has introduced through AM is the use of 3D printed inserts in die casting. Traditional die casting involves long cooling times, which can significantly slow down production. AarKel’s solution? Designing conformal cooling channels within the mold using 3D printing technology. These cooling channels can be placed much closer to the surface of the die, allowing heat to be removed more efficiently.

For example, a typical 100-second cooling cycle can be reduced by several seconds — saving precious time in high-volume production environments. Over the course of thousands of parts, these few seconds translate into substantial productivity gains. Vilas points out that parts ranging from 5-inch cubes to 12-inch inserts can be 3D printed to fit specific areas of the mold that require more precise cooling, improving both efficiency and product quality.

The BMW Case Study: Doubling Insert Lifespan

Vilas shared a compelling case study where AarKel introduced a 3D printed insert into a BMW shock tower mold. The original insert had issues with porosity and die soldering, requiring frequent maintenance after around 50,000 to 60,000 production cycles. By switching to a 3D printed insert, AarKel was able to extend the lifespan of the mold to over 100,000 cycles — doubling its effectiveness and significantly reducing productive time.

However, this innovation came with an unexpected twist. The new inserts were so efficient at cooling that they began creating cold spots in the mold, requiring AarKel to fine-tune the water flow to achieve optimal performance. This case study highlights the balance between innovation and the challenges of refining new processes.

 

Innovating Injection Molding with AM

In addition to die casting, AarKel has also made strides in applying AM to injection molding, focusing on solving common issues like gas traps. Traditionally, gas traps in injection molding create defects in the final plastic components. AarKel's approach was to develop venting solutions using engineered porosity — strategically designed porous slots within the mold that allow trapped gasses to escape without compromising the integrity of the plastic.

In some cases, AarKel combines this venting technique with conformal cooling, creating a dual-purpose insert that both regulates temperature and allows for better gas expulsion. This innovative approach has proven particularly effective in complex parts like automotive speaker grills, which are notorious for gas traps.

Overcoming the Cost Challenge of AM

One of the main challenges companies face when adopting AM is the cost. 3D printing, especially in metal, is often more expensive than traditional CNC machining. However, Vilas explains that AarKel is tackling this issue by investing in multi-laser systems, which speed up production times, and by sourcing more affordable materials. As more companies enter the AM space, competition is driving down the cost of raw materials, making AM more accessible to a broader range of industries.

 

Future Outlook: AM as a Standard in Tooling

Looking ahead, Vilas is optimistic about the future of AM in the tooling industry. He believes that in the next five to seven years, AM will become a standard part of the manufacturing process at AarKel. As printers get larger, materials become more affordable, and the technology becomes more refined, AM will continue to play a critical role in reducing costs, improving efficiency, and enabling more complex designs.

“Additive manufacturing is the way to go,” Vilas states confidently. AarKel’s investment in AM is not just about staying competitive — it's about driving the future of the industry.

Conclusion: Pioneering the Future of Tooling with AM

Fabian wraps up this insightful episode by praising AarKel for their innovative spirit and commitment to advancing the tooling industry through AM. The journey of integrating AM has not been without challenges, but as AarKel has shown, these challenges often lead to breakthroughs in efficiency, product quality, and cost-effectiveness.

Listeners are encouraged to stay tuned to the Additive Snack Podcast for more stories of innovation and to keep an eye on AarKel Tool and Die as it continues to pave the way for the future of manufacturing.

 

Connect with Vilas Ravindra Dulipeta

Discuss all things additive with Vilas on Linkedin.