To Örebro University

This invited speech deals with the design and manufacturing of production tools & dies for stamping of sheet metal parts and cores (inserts) for injection molding of plastic components. Laser-based Powder Bed Fusion (LPBF) is the metal 3D printing (additive manufacturing) method used in this investigation. Solid and topology optimized stamping tools & dies 3D-printed in DIN 1.2709 by LPBF are certified for stamping of up to 2-mm thick hot-dip galvanized DP600 (dual-phase steel sheet). The punch in a working station in a progressive die used for stamping of 1-mm thick hot-dip galvanized DP600 is 3D-printed in DIN 1.2709, both with a honeycomb inner structure and after topology optimization, with successful results. The core (inserts) of an injection mold for production of sofa clips in Polypropylene Homopolymer (PPH) is 3D-printed in DIN 1.2709, conformal cooling optimized and 3D-printed in Uddeholm AM Corrax, and compared with the same core made conventionally. The cooling and cycle time can be improved, if the injection molding core (inserts) is optimized and 3D-printed in Uddeholm AM Corrax. 3D printing results in a significant lead time reduction and improved tool material efficiency. The manufacturing costs of 3D-printed production tools, dies and cores are higher than the costs of those made conventionally. In the case of injection molding, the total costs (the costs of each produced part) are, however, reduced significantly with a 3D-printed core, since the improved cooling reduces the production cycle time. This contribution accounts for the results obtained in the above-mentioned investigations.