3D Printing in Tooling Solutions

Overview

• Conventional production methods often reach limits.
• 3D printing utilized for developing and manufacturing special tooling solutions.

3D Printing Process

• Method Used: Selective laser melting on an in-house Renishaw printer.
• Material: Very fine Moraging steel powder (grain size is 3x smaller than a human hand).
• Build Plate: Clean and measured, used as a fixture for printing.

Printing Procedure

1. Layering Process:
   • Begins with a thin layer of metal powder.
   • Ytterbium fiber laser selectively melts areas of each layer.
   • Process repeats with new layers until the part is finished.
   • Layer Heights: Between 0.03 mm and 0.07 mm.
2. Post-Processing:
   • Excess powder is brushed off and returned to the tank for reuse.
   • Parts are cut from the build plate using a high precision bandsaw.

Tool Manufacturing

• PCD Cutting Inserts:
  • Soldered into 3D printed pockets.
  • Sharpened using DMG Mori LaserTech 20 laser.

Benefits of 3D Printed Tools

• Performance:
  • Up to 50% higher feed rates possible.
  • Achieved reduced cycle times and lower costs due to increased cutting edges.
• Surface Quality:
  • Optimized cutting edges lead to a perfectly finished surface.
  • Significant reduction in burr formation.
• Operational Efficiency:
  • Additively manufactured milling rings enable vibration-free milling operations.
  • Result in longer tool lives.