Functionalized additively manufactured hot forming tools

Purpose and goal

The purpose of the project was to build knowledge and know-how around additively manufactured tool steels. The objectives were to develop additively manufactured hot forming tool materials with functionalized surfaces for optimized tool design, manufacturing process performance and tribological performance. The project objective has been achieved and the results from the work packages have been compiled and implemented in a hot forming tool design process where a tool part for a serial production tool has been redesigned with optimized cooling channels and produced through AM.

Expected results and effects

The project has shown that additively manufactured tool steels have equivalent mechanical properties and wear performance as conventionally produced tool steels. Customized cooling channels can be implemented in hot forming tools and enable more efficient cooling. The effects are increased knowledge of how to design and adapt hot forming tools by utilising the advantages of additive manufacturing. It has also contributed to process optimization for additive manufacturing as well as knowledge of the production of large tool steel components with complex internal structures.

Planned approach and implementation

The project had five work packages for a clear distribution of activities and deliverables in different project phases. The clear roles of the project partners facilitated follow-up and completion of activities. Delays, especially material deliveries, occurred due to the pandemic. Work could progress throughout the project but a six-month extension was sought to complete the validation and implementation steps. A success factor was the need-driven interest among project parties that led to quick turnover of results and that new ideas were explored during the course of the project.