AM Tooling Basics

Using AM techniques to produce tooling allows for some key advantages when compared to traditional manufacturing processes:

• Customization: With AM, it's possible to customize tools for specific tasks or workpieces, even producing one-off or low-volume tooling without the high costs usually associated with custom fabrication.

• Complex Geometries: AM can produce complex internal structures, like conformal cooling channels in molds, which can lead to better thermal management and improved production times.

• Material Savings: Traditional tooling methods, like milling, often waste a significant amount of material. With AM, you build up a part layer by layer, typically using only the material needed for the part.

• Weight Reduction: Using lattice structures or topology optimization, AM tooling can often be lighter than traditional tools while maintaining strength and functionality.

• Integrated Components: In traditional tooling, multiple pieces might need to be machined separately and then assembled. With AM, it's possible to print integrated tooling with fewer separate components, which can lead to stronger and more reliable tools.

• Reduced Lead Time: Traditional tooling can have long lead times, especially for complex or custom tools. AM can significantly reduce these lead times.

• Digital Inventory: Instead of storing physical tools, companies can store digital designs and print the tools as needed.

In industries where rapid tooling changes are necessary or where customization is key, the use of AM for tooling can provide significant advantages over traditional methods. However, the suitability of AM tooling will depend on factors like the specific application, required tool lifespan, available materials, and economic considerations.

AM Tooling refers to anything that is directly utilized in the manufacturing of a product, and includes:

• Tools, which are general devices or implements used to carry out a particular function in manufacturing. With AM, tools can be custom-designed for specific tasks, leading to improved efficiency and precision. The ability to produce tools on-demand can drastically reduce downtime in a production setting.

• Dies, which are specialized tools used in manufacturing to cut or shape material, usually using a press. AM-produced dies can be designed with intricate geometries that might be challenging or costly to achieve with conventional manufacturing techniques. Additionally, the rapid prototyping capabilities of AM allow for swift iterations in die designs.

• Molds, which are containers used to give shape to molten or hot liquid material when it cools and hardens. In industries like injection molding or casting, AM can revolutionize mold-making by incorporating conformal cooling channels that conform to the shape of the mold cavity. These channels enable faster and more uniform cooling, leading to improved product quality and reduced cycle times.

• Jigs/Templates, which assist in controlling the movement or location of tool(s). With AM, jigs can be custom-made to fit specific parts, ensuring precise and consistent manufacturing. This capability is particularly advantageous in industries such as aerospace, where high precision is paramount.

• Fixtures, which hold a workpiece in place as it's being worked on. In many manufacturing scenarios, custom fixtures are necessary for unique or complex parts. With AM, bespoke fixtures can be produced rapidly, facilitating swift changeovers and adaptability to various production requirements.

AM allows for the creation of complex, customizable geometries within tooling designs that would be difficult or even impossible to achieve with traditional manufacturing methods, including:

• Conformal Cooling Channels: In the world of mold design, AM can be used to create intricate cooling channels that follow the contours of the mold. This results in faster and more even cooling, leading to reduced cycle times and improved part quality.

• Lattice Structures: These are complex geometric configurations that are often used to reduce weight while maintaining strength. They can be particularly useful in tooling to achieve lightweight yet robust tools.

• Topology Optimized Designs: Through computational design methods, AM can produce tooling that is optimized for performance and weight, removing unnecessary material while ensuring structural integrity.

• Integrated Multi-part Structures: AM allows for the production of assemblies as a single piece, reducing the need for joints or fasteners. This can lead to stronger tools with fewer points of potential failure.

• Customized Surface Textures: Additive manufacturing can produce surfaces with specialized textures, which can be essential in mold designs where a specific surface finish on the molded part is desired.

However, there are also design constraints that should be taken into account with using AM for tooling, including:

• Anisotropism: Due to the layer-by-layer building process of AM, parts may exhibit different mechanical properties in different directions. This can impact the performance and lifespan of tools and should be considered in the design and orientation phase.

• Material Properties: While AM technologies have made significant advancements, the range of materials available for AM may not match the properties of conventionally manufactured materials. This can influence tool durability and functionality.

• Post-Processing Requirements: Many AM-produced parts require post-processing, such as support removal, surface finishing, or heat treatments. This can add time and cost to the manufacturing process.

• Build Volume Limitations: Each AM machine has a maximum build volume, which limits the size of the tooling components that can be produced. For larger tools, segmenting and joining might be necessary.

• Resolution and Surface Finish: Depending on the AM technology used, there might be limitations in terms of the minimum feature size that can be achieved and the surface roughness. Some applications might require additional finishing operations to achieve the desired results.