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Puzzle Die®

Long life to molds

PuzzleDie® is a groundbreaking mold design approach aimed at significantly increasing mold lifespan and improving the quality of produced parts.

Key advantages
of PuzzleDie®

  • Significant increase in tooling lifetime

    We guarantee at least double the service life compared to traditional configurations.

  • Lower maintenance costs

    The modular design allows for quick replacement of damaged inserts, minimizing downtime and reducing maintenance costs.

  • Optimized cooling system

    Enhanced thermal management of the mold reduces the need for coolant lubricants.

  • Consistent casting quality throughout the mold’s lifespan.
  • Potential reduction in cycle time

    The production cycle can be significantly shortened thanks to optimized solidification times and lubrication phases.

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Horizon 2020 Programme

Costamp, thanks to active collaborations with FEM/CFD simulation providers, has studied and implemented a new design and construction technique for moulds in order to extend their service life like never before. The PuzzleDie® project has been funded through the EU Horizon 2020 Award for research and innovation.

A concrete example

To better illustrate the advantages of the PuzzleDie® approach, here’s a real-world example applied to an existing project for a Steering Housing component. These are the results achieved:

  • Mold life increased from 150,000 to 496,000 shots
  • Cycle time was reduced from 85 to 72 seconds
  • Maintenance cost savings reached 80%