Additive Manufacturing Forming Tool Dies

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional forming tool manufacturing methods are limited in terms of cost-effectiveness and flexibility, particularly in producing tools with complex geometries and varying part configurations, as they often require extensive tooling and long lead times.

Innovation Solution

The method involves manufacturing forming tool dies using additive manufacturing processes, specifically creating first and second die portions with profile panels, baseplates, and perimeter walls, which can be assembled and reconfigured to define forming cavities, allowing for efficient production of complex shapes and reducing tooling costs by reusing die components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional forming tool manufacturing methods are used, then manufacturing process is simple, but manufacturing precision and complexity of geometry are limited

Engineering Contradiction:

Improvecomplexity of geometryVSAvoidmanufacturing process

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces conventional subtractive manufacturing methods with additive manufacturing technology, enabling the creation of complex three-dimensional geometries that cannot be achieved through traditional machining. This substitution allows for direct digital fabrication of dies with intricate internal structures and varying cross-sections, significantly improving manufacturing precision for complex shapes while reducing the need for multiple tooling operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent utilizes the ability of additive manufacturing to vary material parameters and geometric parameters continuously during the manufacturing process. This enables the creation of gradient structures, variable thickness profiles, and optimized lattice patterns within the die components, achieving high manufacturing precision for complex geometries that would be impossible with conventional fixed-parameter manufacturing methods.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If conventional tooling methods are used, then tooling costs are predictable, but lead time is long and flexibility is limited

Engineering Contradiction:

Improvelead timeVSAvoidtooling cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent divides the forming tool into modular die components that can be independently manufactured through additive manufacturing. This segmentation allows each component to be produced separately and quickly, then assembled into the complete tooling system. The modular approach reduces lead time by eliminating the need for machining entire tooling assemblies as single pieces, while the standardization of modular components helps control tooling costs through reuse and reconfiguration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent creates tooling systems with dynamic reconfigurability, where die components can be easily removed, replaced, or repositioned to accommodate different part geometries. This dynamic capability allows the same base tooling structure to serve multiple production needs, significantly reducing lead time for design changes and tooling updates, while the additive manufacturing of complex features reduces the number of components needed, helping to control overall tooling costs.

Inventive Principle:

Principle #15Dynamics

3Reliability

If conventional manufacturing methods are used, then material selection is limited, but ease of manufacture is high

Engineering Contradiction:

Improvedurability of forming surfaceVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent leverages additive manufacturing's ability to process diverse materials including metal alloys, ceramics, and composite materials that would be difficult or impossible to manufacture using conventional methods. This enables selection of materials with superior durability and forming surface properties, such as tool steels with enhanced wear resistance or coated materials with improved release characteristics, while the direct digital fabrication process maintains ease of manufacture by eliminating complex machining operations.

Inventive Principle:

Principle #40Composite materials

4Manufacturing precision

If extensive tooling is used for complex geometries, then manufacturing precision is improved, but device complexity and cost increase

Engineering Contradiction:

Improveaccuracy of complex shapeVSAvoidnumber of tooling components

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent combines multiple tooling functions and geometric features into single integrated die components manufactured through additive manufacturing. Complex internal channels, cooling passages, and structural features that would traditionally require separate tooling components are merged into monolithic structures, maintaining manufacturing precision for complex shapes while reducing the total number of components and simplifying the overall device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20230191665A1Method of manufacturing a forming tool

Publication Date: 2023.06.22 LEAR CORP

AI summary

A method of manufacturing a forming tool. The forming tool may include at least one die having a perimeter wall and a profile panel. At least a portion of the die may be manufactured using an additive manufacturing process. For instance, the profile panel may be manufactured using an additive manufacturing process or the profile panel and additional portions of the die, such as the perimeter wall, may be manufactured using an additive manufacturing process.