Successful demonstration

Fraunhofer researchers construct complex casting tools using 3D printers

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New material and gantry printer ready for practical use

ILT researchers predict that these developments will offer new opportunities in tooling strategy for vehicle manufacturers such as Toyota, who are focusing on fewer individual parts and more complex structures. This means less effort in tool production, longer service life and the possibility of manufacturing several variants with just one tool. Last but not least, the additively manufactured component impressively demonstrates that the newly developed process chain – consisting of a large-format LPBF system, innovative L-40 material and hybrid manufacturing – can meet the practical requirements of industry, even with regard to giga casting. However, the potential extends far beyond this individual case! According to the Aachen-based company, the developed process chain is not only suitable for large aluminium HPDC tool inserts, but also for most other hot and cold forming tools, as well as for insert components for punching, thread production or injection moulding. This means that wherever highly stressed tools with complex cooling and limited batch sizes are required, additive manufacturing can bring significant advantages to the manufacturing process in the future thanks to this development.

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