Businesses have increasingly adopted 3D printing into their manufacturing processes. While many companies have used 3D printing - also known as additive manufacturing - for prototyping and concept modeling, some may not be aware of the benefits of using the technology to produce functional, end use parts and manufacturing tools like jigs and fixtures. With an expanded selection of durable materials, additive manufacturing can build parts capable of withstanding high pressures and repeated use.
Metalforming is one manufacturing method that can be improved when used in tandem with additive manufactured tools. Instead of relying on CNC-machined dies and forming tools for processes like hydroforming and rubber pad pressing, the metalforming industry is turning to additive manufacturing to streamline the production of metal parts by improving tool design efficiencies and lowering costs.
Design Freedom and Flexibility
The benefits of additive manufacturing begin with part design. "Unlike traditional manufacturing methods, which limit geometrical features like holes, undercuts and uneven wall thicknesses, fused deposition modeling (FDM) metalforming tools are built layer by layer, allowing them to include these structures in a single part without multiple assemblies," said a Stratasys Direct Manufacturing spokesperson. "With a process like CNC machining, these structures would either be impossible to build or would require multiple set-ups and secondary operations to achieve, likely leading to increased costs and delayed production. Instead, the design freedom of additive manufacturing allows for the creation of complex tools based on functionality first and foremost."
This newfound freedom is not limited to CAD files, either. "Additive manufacturing allows the building of parts more quickly than traditional processes - think days, not weeks or months - providing the ability to print tools on demand and begin production sooner," said the spokesperson. Tool designs can also be tweaked on the fly: if a tool needs modification, just update the design file and a new one can be printed immediately. The digital nature of design files allows the user to amass a digital rather than physical inventory of tools, freeing up additional storage space in the shop since forming tools can be printed as needed.
Tough Parts Lead to Efficient Processes
While additive manufacturing provides numerous benefits to designs and production, metalforming tools are only effective if they are made with materials capable of withstanding the repeated use and the pressures inherent to the metalforming process. "Additive manufacturing can deliver these tough parts, since additive processes like FDM build parts using some of the same strong thermoplastics available for injection molding," said the spokesperson.
For metalforming applications, FDM thermoplastics like ABS, polycarbonate and ULTEM have been tested with a wide range of metals, including aluminum alloys and stainless steels. FDM tools made from these materials can last for hundreds of cycles with little sign of wear and tear. High-strength ULTEM is capable of withstanding pressures up to 10,000 PSI for hydroforming applications and rubber pad pressing applications up to 1,000 tons.
Not only are FDM metalforming tools strong enough for the job, but using them can also make metal part production more efficient. One of the major challenges of metalforming is dealing with trapped air pockets between the sheet metal and CNC-machined die. With FDM, this issue is eliminated because the tools are naturally porous, allowing the operator to pull the metal close to the die. Tools made with FDM thermoplastics also do not adhere to the metal, eliminating the need to lubricate sheet metal blanks and helping speed up production.
Take Production to the Next Level
Realizing the benefits of additive manufacturing for metalforming processes can be done in two ways: either by purchasing a system to build tools in-house or by working with a service organization that can build tools and consult on how best to incorporate them into current production practices for metal parts. "Regardless of the path chosen, additive manufacturing can help improve the way parts are made," said the spokesperson.
Authored by Bill Camuel, Project Engineering Manager, Stratasys Direct Manufacturing
For more information contact:
Stratasys Direct Manufacturing
28309 Ave Crocker
Valencia, CA 91355
888-311-1017 / 661-295-4400
info@stratasysdirect.com
www.stratasysdirect.com