Optimization of selective laser melting for application to automotive tooling

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Exco Engineering, an Ontario based world leader in the design and fabrication of tooling for high pressure die casting, has recentlyinitiated significant R&D to adopt Additive Manufacturing (AM) for producing molds and dies. AM refers to a class of industrialtechnologies that build objects layer-by-layer directly from digitized geometry as opposed to subtractive or formative manufacturingmethods. It is believed that AM will disrupt current manufacturing processes due to its distinct advantages in creating complexinternal structures impossible to produce by conventional machining. In high pressure die casting, AM enables complex coolingchannels that match the profile of the final component to be integrated into the steel die, improving thermal management andultimately improving quality, production rates, and die longevity.Through this academic-industry partnership, we aim to develop technical knowledge to improve three aspects of metal AM for toolsteel applications: reproducibility, process window for high quality, and costs. Specifically, we will (1) characterize powder size andmorphology to understand the effects of reuse times; (2) optimize process parameters to reduce build time while maintainingdesired mechanical properties; and (3) investigate hybrid manufacturing whereby critical sections such as those with conformalcooling are 3D printed onto an already existing bulk component. This project will enable Exco Engineering to maintain competitiveadvantage in the tool/die industry, retaining jobs and increasing revenue, while providing McMasters research team with newknowledge and experience related to the industrial application of metal AM, and in-service behaviour of this emerging and key newmanufacturing technology.