Additive manufacturing tooling for the automotive industry

Leal, Rui M.; Barreiros, Fátima M.; Alves, M.L.; Romeiro, F.; Vasco, Joel; Santos, Marco Aurélio Reis dos; Marto, C.

doi:10.1007/s00170-017-0239-8

Cited by 284 publications

(129 citation statements)

References 17 publications

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“…The number of metallic materials that can be used to 3Dprint tools, dies and molds is still limited [9]. Among these few existing powder metals, the maraging steel DIN 1.2709 is held to be applicable in tool making for stamping [5]. This investigation focuses on the performance of solid and topology optimized stamping tools and dies 3D-printed in DIN 1.2709.…”

Section: And 2)mentioning

confidence: 99%

“…In [5], inserts in a body panel stamping tool were 3Dprinted in maraging steel DIN 1.2709. The 3D-printed inserts exhibited the same performance as the conventionally made, however, with reduced lead time and minimized internal process logistics [5]. In the present study, AM is certified industrially and attempts are made to accomplish further improvements by topology optimization of the stamping tools.…”

Section: Introductionmentioning

confidence: 99%

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Production Tools Made by Additive Manufacturing Through Laser-based Powder Bed Fusion

Asnafi

Rajalampi²,

Aspenberg³

et al. 2020

Berg Huettenmaenn Monatsh

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This paper deals with the design and production of stamping tools and dies for sheet metal components and injection molds for plastic components. Laser-based Powder Bed Fusion (LPBF) is the additive manufacturing method used in this investigation. Solid and topology optimized stamping tools and dies 3D-printed in DIN 1.2709 (maraging steel) by LPBF are approved/certified for stamping of up to 2-mm thick hot-dip galvanized DP600 (dualphase steel sheet). The punch in a working station in a progressive die used for stamping of 1-mm thick hot-dip galvanized DP600 is 3D-printed in DIN 1.2709, both with a honeycomb inner structure and after topology optimization, with successful results. 3D printing results in a significant lead time reduction and improved tool material efficiency. The cost of 3D-printed stamping tools and dies is higher than the cost of those made conventionally. The core (inserts) of an injection mold is 3D-printed in DIN 1.2709, conformal cooling optimized and 3D-printed in Uddeholm AM Corrax, and compared with the same core made conventionally. The cooling and cycle time can be improved, if the injection molding core (inserts) is optimized and 3D-printed in Uddeholm AM Corrax. This paper accounts for the results obtained in the above-mentioned investigations.

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Section: And 2)mentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Production Tools Made by Additive Manufacturing Through Laser-based Powder Bed Fusion

Asnafi

Rajalampi²,

Aspenberg³

et al. 2020

Berg Huettenmaenn Monatsh

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“…Although additive manufacturing (AM) has existed for decades and has already revolutionized the production of polymeric material components, new AM technology developments are providing industries with the possibility of building structural components with a variety of metal alloys, ceramics, and composite materials. The major drivers of interest (Table A1 in Appendix A) that have led to the introduction of metal AM processes in such industrial sectors as the aerospace [1], automotive, defense, jewelry, medical [2], and tool making [3] fields, are the significant reduction in the lead times of the components, innovative designs with higher strength, lower weight and fewer potential failure points from joining features, and reduction of waste material [4,5].…”

Section: Introductionmentioning

confidence: 99%

A Metal Powder Bed Fusion Process in Industry: Qualification Considerations

2019

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An additive manufacturing process should produce repeatable results as far as the properties of the material and the geometric dimensions that have to be adopted by a company as a production method are concerned. This represents a challenge for such high-volume sectors as the automotive industry, where quality and reliability are extremely important. One way of addressing this challenge is to qualify the process. A common framework has here been identified starting from the analysis of the factors that influence the stability of the result in the main phases of metal powder bed fusion (PBF) processes. A qualification procedure (QP), which offers possible solutions to help reduce risk factors, has been proposed. This procedure is independent of the industrial sectors, of which type of materials and metal PBF processes, and of the manufacturer of the used PBF system.

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“…Esse tipo de processo de fabricação foi introduzido pela primeira vez em 1986 com o advento do processo de Estereolitografia (Stereolithography -SLA) por meio da patente de Charles Hull [1]. Atualmente, a AM já é utilizada em diversas áreas como a área automotiva [2], aeroespacial [3] e médica [4,5], sendo a estereolitografia um dos processos de AM mais utilizados nos dias de hoje [6]. Essa técnica tem o potencial de ser útil em diversas aplicações como, por exemplo, na área de microfluídica [7], Sistemas MicroEletroMecânicos (Micro Electrical Mechanical Systems -MEMS) [8], estruturas porosas para tecidos vivos [9,10] e moldes [11].…”

Section: Introductionunclassified

Manufatura aditiva por estereolitografia: análise da geometria da peça e da influência da posição e orientação de fabricação

Coelho¹,

Araujo²,

Thiré³

2018

Matéria (Rio J.)

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RESUMO A estereolitografia é um dos processos de manufatura aditiva mais utilizados e utiliza resina líquida fotopolimerizável como matéria-prima. Por meio de uma reação de cura, cada camada desta resina é transformada para o estado sólido. Como qualquer tipo de processo de fabricação, a estereolitografia tem suas limitações e dificuldades, a mais comum é a contração dimensional das peças fabricadas durante a polimerização. É possível reduzir este defeito analisando os parâmetros que influenciam o fator de contração das peças produzidas, porém não foram encontrados estudos científicos que quantifiquem a influência da orientação da peça e se há influência da posição na plataforma. Neste artigo, a contração de peças fabricadas foi quantificada e a análise de variância dos resultados em diferentes orientações e localizações foi realizada. De acordo com os resultados, verificou-se que a localização das peças na plataforma é um fator importante em função das orientações das dimensões das geometrias fabricadas e portanto deve ser compensado de forma não homogênea para corrigir este defeito.

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Additive manufacturing tooling for the automotive industry

Cited by 284 publications

References 17 publications

Production Tools Made by Additive Manufacturing Through Laser-based Powder Bed Fusion

Production Tools Made by Additive Manufacturing Through Laser-based Powder Bed Fusion

A Metal Powder Bed Fusion Process in Industry: Qualification Considerations

Manufatura aditiva por estereolitografia: análise da geometria da peça e da influência da posição e orientação de fabricação

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