*2.2.5 Direct metal laser sintering*

Direct metal laser sintering (DMLS) from EOS consists of metal powders processed directly in a laser sintering machine. The machine manufactures not only tool inserts but also metal parts. Two materials are available for DMSL method and this method depicted in **Figure 4**:


**95**

*2.2.7 Lens*

*2.2.6 Laminated tooling*

*DMLS 3D printing process [9].*

**Figure 4.**

Laminated tooling is another applicable option to construct cavities on an AM used prototyping machine. By using a CAD model, sheet layers of metal are sliced, which uses comparable principles to the laminated object manufacturing (LOM) method to multiply slices. Either water-jet or laser cutting techniques are usually applied to obtain the profiles. Manufacturing the molding tool requires CAD model to take the form of the necessary cavity. A mass of laminates can be accomplished to replicate by cutting all the cavity slices into sheet metal. To eliminate complicated post-process cutter path planning, a pseudo-solid cavity in hardened tool steel is manufactured by using either clamping or diffusion bonding related picture can be seen in **Figure 5** [6].

The Optomec (Albuquerque, New Mexico) laser-engineered net shaping (LENS) system—initially created at the Sandia National Laboratories—is used to build elements into a laser, primarily laser cladding using a metal powder feed. Through a highly intense laser beam into a molten metal pool, a metal powder is injected in this method. The manufacturing method takes place for oxygen-free operation in a low-pressure argon chamber. A movement scheme drives a platform through x and y planes (two-dimensional) as the laser beam traces the cross section

Albrecht Röders GmbH & Co. KG (Soltau, Germany) has marketed a method called controlled metal buildup (CMB). At the Fraunhofer Institute for Production

of the fabricated portion which can be seen in **Figure 6** [7].

*2.2.8 Controlled metal buildup (CMB)*

*Utilization of Additive Manufacturing to Produce Tools DOI: http://dx.doi.org/10.5772/intechopen.89804*

*Utilization of Additive Manufacturing to Produce Tools DOI: http://dx.doi.org/10.5772/intechopen.89804*

*Design and Manufacturing*

*2.2.4 EBM tooling*

*DTM SLS Sinterstation 2500 plus [8].*

**Figure 3.**

heat-treated products [7].

*2.2.5 Direct metal laser sintering*

method depicted in **Figure 4**:

elements in various products.

of up to 100,000 plastics [7].

a tool. All sintering process happens among the polyamide powder particles. This technique provides improvements in toughness of items unlike some of the other smooth tooling techniques and heat transfer. The copper is not only appropriate for these properties but also can offer some advantages to users like operating a device with pressure and temperature settings which are closer to the environment of the

Arcam provides technology to manufacture completely solid metal elements with electron beam melting (EBM). Parts layer by layer are made by the EBM technology using strong electron beam (4 kW power), which melts metal powder. The use of EBM method performed in a vacuum provides users with stress relaxed components with better mechanical, chemical, and material properties the casting and forming. The method depends on the use of high-level energy thanks to its ability to provide high fusion ability and high productivity. The EBM method is mainly developed in order to process refractory as well as resistant materials (tantalum, niobium, molybdenum, tungsten, vanadium, hafnium, zirconium, titanium) and alloys thereof. It is defined primarily by not only high-speed manufacturing but also complicated geometries of elements with comparable mechanical characteristics to

Direct metal laser sintering (DMLS) from EOS consists of metal powders processed directly in a laser sintering machine. The machine manufactures not only tool inserts but also metal parts. Two materials are available for DMSL method and this

1.Bronze-based materials are preferable for injection molding of up to 1000

2.Steel-based material which is advantageous for injection molded components

process. The main inconvenience of it is the material's low resistance [7].

**94**

**Figure 4.** *DMLS 3D printing process [9].*

#### *2.2.6 Laminated tooling*

Laminated tooling is another applicable option to construct cavities on an AM used prototyping machine. By using a CAD model, sheet layers of metal are sliced, which uses comparable principles to the laminated object manufacturing (LOM) method to multiply slices. Either water-jet or laser cutting techniques are usually applied to obtain the profiles. Manufacturing the molding tool requires CAD model to take the form of the necessary cavity. A mass of laminates can be accomplished to replicate by cutting all the cavity slices into sheet metal. To eliminate complicated post-process cutter path planning, a pseudo-solid cavity in hardened tool steel is manufactured by using either clamping or diffusion bonding related picture can be seen in **Figure 5** [6].

#### *2.2.7 Lens*

The Optomec (Albuquerque, New Mexico) laser-engineered net shaping (LENS) system—initially created at the Sandia National Laboratories—is used to build elements into a laser, primarily laser cladding using a metal powder feed. Through a highly intense laser beam into a molten metal pool, a metal powder is injected in this method. The manufacturing method takes place for oxygen-free operation in a low-pressure argon chamber. A movement scheme drives a platform through x and y planes (two-dimensional) as the laser beam traces the cross section of the fabricated portion which can be seen in **Figure 6** [7].

#### *2.2.8 Controlled metal buildup (CMB)*

Albrecht Röders GmbH & Co. KG (Soltau, Germany) has marketed a method called controlled metal buildup (CMB). At the Fraunhofer Institute for Production

**Figure 5.** *Laminated tooling process [10].*

#### **Figure 6.**

*Laser-engineered net shaping (LENS) process [11].*

Technology (IPT) (Aachen, Germany), the fundamental technology was initially created. Three systems were purchased by the business last year.

Components having 100% density are resulted by using this method covering lased cladding and friction. The material is deposited by CMB from a steel wire, and a 1–2 kW HDL laser welds the steel to the workpiece surface. Before every fresh layer is deposited, a cutter with a high speed is used to flat each layer [6].

**97**

*2.2.9 ProMetal*

**Table 3.**

**Table 3** [12].

*2.2.10 Direct SL shell tooling*

*Utilization of Additive Manufacturing to Produce Tools DOI: http://dx.doi.org/10.5772/intechopen.89804*

*Advantages and disadvantages of direct methods which use AM.*

The ProMetal AM used tool production system of Extrude Hone—named RTS-300—is 3DP method for the manufacture of metal components and tooling. Steel parts up to size of 12 '12 '10 inches (300 '300 '250 mm) can be achieved by the machine. ProMetal applications covers vacuum forming, lost foam patterns, injec-

Thin SL shells in shell tooling are applied to manufacture inserts reinforced by materials with high thermal conductivity like aluminum-filled epoxy. Therefore, higher mold strengths are attainable in contrast to those achieved by the direct AIM tooling technique, which builds a strong resin mold. Due to aluminum's increased conductivity, which offers faster cooling of mold, the cycle time gets shorter. To improve wear resistance, metal plate can be used to cover the outer surface brief advantages/disadvantages chart of direct methods is depicted in

**3. Design of deep drawing tools produced by rapid tooling technologies**

In all industries, customized and tailored design is gaining importance, and therefore small series production has increased in the last decade. The increasing number of variant types and also the decreasing number of the same parts affect the manufacturing processes deeply. For instance, metal forming is known to be economical for large series production. One of the main factors affecting the cost of the metal forming process is tool costs. Conventional methods and materials

tion molding, blow molding, and powder metal part manufacturing [6].


#### **Table 3.**

*Design and Manufacturing*

**96**

**Figure 6.**

**Figure 5.**

*Laminated tooling process [10].*

Technology (IPT) (Aachen, Germany), the fundamental technology was initially

Components having 100% density are resulted by using this method covering lased cladding and friction. The material is deposited by CMB from a steel wire, and a 1–2 kW HDL laser welds the steel to the workpiece surface. Before every fresh

created. Three systems were purchased by the business last year.

*Laser-engineered net shaping (LENS) process [11].*

layer is deposited, a cutter with a high speed is used to flat each layer [6].

*Advantages and disadvantages of direct methods which use AM.*

## *2.2.9 ProMetal*

The ProMetal AM used tool production system of Extrude Hone—named RTS-300—is 3DP method for the manufacture of metal components and tooling. Steel parts up to size of 12 '12 '10 inches (300 '300 '250 mm) can be achieved by the machine. ProMetal applications covers vacuum forming, lost foam patterns, injection molding, blow molding, and powder metal part manufacturing [6].
