3D Printing for Tooling and Molds: Enhancing Efficiency and Precision in Manufacturing Workflows

3D printing for tooling and molds enhances manufacturing efficiency and precision while minimizing prototyping and production costs.

3D printing is often talked about as an alternative to traditional manufacturing techniques like molding and machining. After all, it offers unique advantages over those processes like very short lead times and design freedom. However, 3D printing is sometimes at its most effective when it assists traditional techniques, not when it replaces them.  

3D printing for tooling and molds is one of the most important applications of additive manufacturing technology, alongside prototyping and part production. Various printing technologies can be deployed to fabricate essential manufacturing aids like work-holding devices, molds, dies, and more, leveraging the key advantages of 3D printing in combination with existing technologies.

This article looks at the advantages of 3D printing for tooling and molds, discussing real-world examples and future trends.

The Role of Tooling and Molds in Manufacturing

Tooling is a general term used to describe a set of devices used in manufacturing to achieve manufacturing efficiency and consistency between parts. Unlike the machinery with which they are used, tools are often specific to the end-use parts being made.

Some examples of tooling in manufacturing include:

• Molds: used to shape molten material into specific forms by injecting or pouring it into a mold cavity where it cools and solidifies into the desired part

• Inserts:  Interchangeable sections of a mold that can be swapped out to change the geometry of the molded part, allowing for customization and flexibility

• Dies: Tools used to cut or shape materials into specific forms through a range of mechanical processes

• Patterns: Replicas of parts used to create molds or shapes for various production processes

• Jigs: custom fixtures that guide the cutting or assembly of a part, ensuring precision and repeatability in manufacturing processes like drilling or welding

• Fixtures: Work-holding devices used to securely hold a workpiece in place and ensure accuracy and consistency  

• Inspection Aids: Devices used to assist in the inspection and quality control of manufactured parts and assemblies

• End effectors: devices or tools attached to the end of a robotic arm or automated machine that interact with the environment to perform specific tasks  

While these different devices have different functions, they are all used to make manufacturing processes faster, simpler, more consistent, and safer for operators.  Tooling is used across a range of manufacturing processes. For example, molds are an integral part of injection molding and casting, dies are used in many sheet metal forming processes, and fixtures are used in machining.  

Advantages of 3D Printing for Tooling and Molds

3D printing for tooling and molds is an important part of the additive manufacturing industry, covering a range of 3D printing processes, materials, and applications. In general, 3D printing can benefit tooling production due to its speed, low cost for one-off parts and small batches, and design freedom.  

Manufacturing Efficiency

3D printing tooling can be integrated into a manufacturing workflow with relative ease. Traditional toolmaking and moldmaking techniques are typically slower and more labor-intensive than 3D printing, leading to manufacturing delays.  On the other hand, many 3D printing systems are portable, enclosed, and can be installed close to the factory floor, reducing any latency between tooling and part production.  

Enhanced Precision and Design Freedom  

While traditional processes like machining are capable of achieving tight tolerances on tooling, 3D printing offers a high level of precision and design flexibility.

Processes like Stereolithography produce an excellent resolution and surface finish, suitable for applications like molding patterns, while several printing processes are capable of printing molds with complex internal geometries that assist cooling.

Practical Applications and Case Studies

Different 3D printing technologies suit different tooling applications. Some key processes and suitable applications are listed below:  

• Binder jetting: Can be used to produce highly detailed, large-scale sand molds and cores for metal casting.

• Stereolithography: Can be used to produce sacrificial patterns for lost wax casting, ideal for small-scale jewelry production

• SLS and high-temperature FFF: Can be used to produce tough, wear-resistant manufacturing aids such as jigs and fixtures from materials like nylon and PEEK

• Metal AM: Processes like DMLS and metal extrusion can be used to fabricate injection molds with integrated conformal cooling channels

Real-world instances of 3D printed tooling can be found far and wide. For instance, German carmaker Audi recently used UltiMaker FFF 3D printers to make 200 different tools, jigs, and fixtures during production of its Audi E-Tron GT electric car. Most of the manufacturing aids were made from Tough PLA or flexible TPU.

Elsewhere, Dutch molding company Promolding has used Stratasys material jetting printers to 3D print prototype injection molds for final product validation or concept development. The company was able to make printed molds in three days, significantly faster than the six-week lead time for conventionally produced molds.

Future Trends in 3D Printing for Tooling and Molds

Advances in 3D printing technology will likely contribute to an increased use of the technology for tooling and molds.  

However, it is perhaps molds that will benefit the most from improved 3D printing processes and materials, as today’s printed molds are typically only fit for prototyping. Significant advances in metal AM technologies like powder bed fusion and binder jetting could ultimately lead to more durable molds suitable for mass production.  

Conclusion

3D printing for tooling and molds offers a way for manufacturers to increase their efficiency on the factory floor, often without major investment, leading to more precise and repeatable manufacturing processes.

Discover Madeinadd’s 3D printing services for jigs, fixtures, molds, and more.

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