Multilayered thermally sprayed heating coating systems on model tools for injection molding

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Benedikt Schmidt, schmidt@iot.rwth-aachen.de, Institut für Oberflächentechnik IOT; Prof. Dr.-Ing. Kirsten Bobzin, info@iot.rwth-aachen.de; Marvin Erck, erck@iot.rwth-aachen.de, Surface Engineering Institute, RWTH Aachen University; Kevin Jasutyn, jasutyn@iot.rwth-aachen.de, Surface Engineering Institute, RWTH Aachen University; 

https://doi.org/10.53192/ITSC2026553

Warpage, caused by uneven cooling across the tool geometry, remains a major challenge in modern injection molding. Compensation requires localized and rapid heating adjusted to the molding cycle times. Thermally sprayed resistive heating systems fulfill these conditions and allow for surface level heating of tools as shown in previous works. To investigate the application for complex mold geometries, a mold-like demonstrator featuring internal cooling channels was coated with a TiOx based ceramic heating coating system using Atmospheric Plasma Spray (APS) and electrically connected with High Velocity Oxy-Fuel (HVOF) sprayed NiCr20 conductive paths. The combination of surface-level heating and internal cooling enables cycle times as short as 16 s and a durability of multiple thousand heating cycles. This marks a significant step towards the implementation of the thermally sprayed heating coatings for warpage compensation and the use of more sophisticated thermally sprayed circuits.

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Erscheinungsdatum

March 2026

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