Meaning
Specialized additive manufacturing process utilizes high-alloy steels to create complex molds, dies, inserts, and cutting tools. Manufacturers use tool steel printing to produce geometries with internal cooling channels that are impossible to achieve through traditional machining. The process requires precise control of the thermal history to prevent the formation of cracks in the brittle martensitic structure.
Post-processing steps like heat treatment are usually required to reach the final hardness.
Design Freedom
Inclusion of conformal cooling channels within the tool body substantially reduces the cycle time in injection molding applications. These channels follow the contour of the part, providing more uniform heat removal than straight drilled holes. This capability of tool steel printing improves the quality of the molded parts and extends the life of the tool itself.
Complex internal structures also allow for weight reduction without sacrificing stiffness. Advanced software tools assist in the optimization of these geometries to ensure they can withstand the high pressures of the molding process.
Thermal Management
High temperature preheating of the build plate is often necessary during tool steel printing. This reduces the thermal gradient between the freshly melted layer and the rest of the part, minimizing residual stress. Controlling the cooling rate after the build is finished is also essential for avoiding the formation of untempered martensite.
Production Cost
Initial investment in 3D printing equipment is offset by the reduced lead time for custom tooling. Instead of waiting weeks for a machined part, a tool steel printing project can be ready for testing in a matter of days. The ability to repair or modify existing tools by adding material to specific areas further enhances the economic value of the technology.
