Applying Additive manufacturing to Aluminum tool part design

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Additive Manufacturing (AM) refers to an emerging class of technologies that build 3D objects by the controlled addition of materials in a layer-by-layer fashion, at or near their final shape, with or without complex internal structures, using a minimum amount of machining. Dies and molds, from the numerous thermal gyrations imposed during operation, could have their performance improved by the availability of technologies permitting to maintain a uniform temperature field. AM is becoming an enabling manufacturing technology capable of providing such advantages by the insertion of conformal cooling channels in strategic locations. This integrated thermal management concept will allow a reduction in the duty cycle (increased production rate), an increase in the processing capacity and an improvement of the profitability. However, most of the fundamental concepts in the design and manufacturing of such dies and molds remain to be defined. In that context, this joint NSERC-CQRDA proposal is established to define: (1) optimized methods for design for additive manufacturing (DFAM) of tooling with thermal management systems, (2) how to fabricate such tools and dies with complex cooling channel systems using new high strength/high thermal conductivity powders and (3) how to obtain surfaces with compatible characteristics for the Al forming industry. These fundamental knowledge gaps will be answered during this project. The availability of such high-performance toolings is of key interest to the industrial sponsors of this project, namely Verbom, Exco Engineering, Trumpf and AlTec. All of them will benefit by improving their competitiveness and product portfolio, leading to the ultimate goal of business growth, which will contribute to improving Canada's position in the adoption rate of AM technologies in the tooling and transportation sector.