WHY USE DIE-BOND?
Conformal Cooling in conjunction with Die-Bond’s LID Bonding process reduces energy, saves on cycle times, reduces material usage and helps keep manufacturing in the USA!

Conformal cooling is not new, but Die-Bond LLC offers a new technology to bond molds or mold inserts that can substantially reduce cycle times.  Moldmakers requiring conformal cooling for molds will benefit even more using Die-Bond’s proprietary LID Bonding process.  Advantages include:
  • eliminating the need for water line plugs for the drilled holes, and thereby the potential for plug leaks or corrosion. 
  • A smaller insert footprint allows moldmakers to use the same size mold base for more cavities, thus providing the opportunity to use a smaller-tonnage press yet get higher yield rates.
  • A near parent-metal bond strength.
  • A less brittle mold (no thick braze alloy fillets).
  • A near 100% part yield due to improved flatness and hermetic sealing qualities post-bond.
  • Warpage problems are eliminated.
MOLD COST SAVINGS:
If you require 16 mold inserts, you would typically need to make spares to allow for expected yield losses using the conventional vacuum braze process.  If your cost per insert for braze alloy is $11,000.00 ($10,000 for your work to make each insert and $1,000 for the braze alloy process) each, then your total cost would be $176,000.00.  How many extra inserts would your company make as a backup?  Multiply that by $11,000.00.  With Die-Bond’s there is no need to make additional inserts.

Stated Norman Hubele, President of Die-Bond LLC:  “ A  mold manufacturer that needed conformal cooling for 50 inserts sent Die-Bond 70 units to allow for typical expected loss, being used to conventional brazing.  We sent them back 70 good inserts.  Every time they send Die-Bond a run they now save 30%.  The cost and environmental impact savings is immediate!”

While costs may vary depending upon the configuration of the insert and the number of pieces needing bonding, the proven cost savings, material and processing savings using the Die-Bond LID vacuum bonding process are undeniable.

As an Injection Molder, here is an example of costs savings:

Typical hours for a run of 1 million parts in a 16 cavity mold at a 10second cycle (baseline – 138,240 parts/day x 7.5 days = 1,036,800 parts x $50/hr. molding press rate w/1 operator = 180 hours = $9,000.00 total CTM*)

Potential Cycle-Time
Savings
Total Parts/ day x 5 Days x $50/hr.
JUST 1 SECOND 207,360 1,036,800 parts $6,000.00 CTM*

* Cost-to-Manufacture

Depending on the thickness of the part as well as the composition of the plastic, greater cool-down rates may be realized. We have demonstrated up to 20X improvement in cool-down times.    
The only conformal cooling assembly method for your company
should be Die-Bond’s LID Bonding process.
 
DIE-BOND LLC           6141 W. Erie St. Chandler, AZ 85226-2635         480-940-0024 (phone)      480-940-0023 (fax)
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