Recent advancements at the Department of Energy’s Oak Ridge National Laboratory show that 3D-printed metal molds offer a faster, more cost-effective and flexible approach to producing large composite components for mass-produced vehicles than traditional tooling methods.
The research, conducted at the Manufacturing Demonstration Facility, or MDF, at ORNL, confirms that large-scale additive manufacturing is well-suited for creating complex metal molds, with efficiencies that could accelerate the adoption of lightweight composite materials in the automotive sector.
“This kind of technology can help reindustrialize the U.S. and boost its competitiveness by creating smarter, faster ways to build essential tools,” said lead researcher Andrzej Nycz with ORNL’s Manufacturing Robotics and Controls group. “It brings us closer to an automated, intelligent production process.”
Traditionally, metal tools are made by subtracting material from large, forged steel blocks — a process that removes up to 98% of the original material, generates significant waste and often takes months due to supply chain delays. In contrast, additive manufacturing deposits metal layer by layer, using widely available welding wire as a feedstock and minimizing waste to about 10%.
The mold was installed on a Wabash MPI 150-ton hydraulic press at the University of Tennessee, Knoxville, Fibers and Composites Manufacturing Facility. Credit: University of Tennessee, Knoxville
Additive manufacturing also allows engineers to produce more complex mold geometries, such as internal heating channels, that would be difficult to achieve usingconventional machining.
“The more complex the shape, the more valuable additive manufacturing becomes,” Nycz said.
The research team partnered with Collaborative Composites Solutions, or CCS, operator of IACMI–The Composites Institute, to put the concept to the test. They chose to 3D print a large battery enclosure mold, complete with intricate internal features.
Using a gas metal arc welding, or GMAW, additive manufacturing process at Lincoln Electric Additive Solutions, two near-net-shape dies were printed from stainless steel ER410 wire. The GMAW process uses an electric arc to melt a consumable wire electrode to build up metal layers and create complex components while using a protective shielding gas to prevent contamination. The team applied a specialized toolpath strategy for weight reduction while maintaining strength.
Subsequent analysis confirmed the lightweighted mold met structural performance requirements, validating the feasibility of additive manufacturing for high-performance production tooling.
The lower mold, on the left, and the upper mold are shown fully assembled. Credit: IACMI
Subsequent analysis confirmed the lightweighted mold met structural performance requirements, validating the feasibility of additive manufacturing for high-performance production tooling.
The project was funded by DOE’s Advanced Materials and Manufacturing Technologies Office, or AMMTO. Additional researchers who contributed to this project include John Unser from Composite Applications Group, Peter Wang from ORNL, and Jason Flamm and Jonathan Paul from Lincoln Electric Additive Solutions.
The MDF, supported by AMMTO, is a nationwide consortium of collaborators working with ORNL to innovate, inspire and catalyze the transformation of U.S. manufacturing.
UT-Battelle manages ORNL for DOE’s Office of Science, the single largest supporter of basic research in the physical sciences in the United States. The Office of Science is working to address some of the most pressing challenges of our time. For more information, please visit energy.gov/science.
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