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Description of the component:
A fully resilient edging tool made of A2 tool steel was additively manufactured for in-house sheet metal production for use on a TruBend 5230 bending machine. Metal-X from Markforged was used as the 3D printing process.
Challenges:
BAM has maximum demands on quality and flexibility for tools, some of which can only be met through in-house production. From design to the use of tools manufactured in-house, BAM covers the entire value chain. However, machining processes are complex and cost-intensive, especially in prototyping. Additive manufacturing technologies are therefore ideal for the efficient production of functional prototypes.
Solution:
Using 3D printing - in this example with A2 tool steel - the production of innovative components in small quantities can be massively accelerated and made more efficient. At the same time, additive manufacturing technologies offer enormous advantages in terms of weight optimization. Thanks to a honeycomb structure inside the component, it was possible to save weight while maintaining the same geometry and stability. The self-designed edge tool for the TruBend 5230 bending machine from Trumpf was additively manufactured overnight. Following the design, an STL file of the component was created in order to import it into the print manufacturer's cloud-based software. There, the tool was prepared for printing (wall thickness, internal structure, etc.). The printing process could be started with a click of the mouse. After printing, the software-controlled washing and sintering process followed. The component was ready for use immediately after sintering. Another impressive feature was the easy handling of the material change by simply replacing the material rolls. Thanks to Markforged's Atomic Diffusion Additive Manufacturing (ADAM) technology, the component has excellent mechanical properties and high rigidity. As the A2 tool steel is air-hardened, the material is highly impact-resistant. The load-bearing capacity of the edge tool is in no way inferior to that of a conventionally manufactured tool. The fundamental advantage for component optimization lies in the freedom of design: additive manufacturing means that there are virtually no restrictions regarding the geometric complexity of a component. This is crucial for making components lighter and optimizing them for a specific application. By processing continuous fibers, it was possible to give the component more performance in terms of strength - while at the same time achieving an excellent surface quality.
Conclusion:
The edge tool described above demonstrates the advantages of 3D printing compared to CNC manufacturing: In machining production, increasing the complexity of a component leads to additional costs and longer delivery times. With additive manufacturing technologies, it is possible to reduce the weight of components and thus contribute to reducing costs and increasing efficiency. As the next functional prototype for its machinery, BAM GmbH is planning a sinking electrode for a die-sinking EDM machine made of pure copper. Copper of 99.8 percent purity with very high thermal and electrical conductivity can be printed with significant design freedom.