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FKM areas of application

Rapid tooling in 3D printing

FKM consulting,
services and co-engineering

Rapid tooling in metal

In additive manufacturing, rapid tooling is a faster, more cost-efficient and more flexible way to produce tools and moulds than, for example, machining or casting. It provides companies that need to respond faster and more efficiently to changing customer needs with a clear competitive advantage.

5

advantages

Our consulting and implementation approach

When it comes to rapid tooling, FKM also sees itself as a project partner that supports customers beyond the additive manufacturing procedure. We therefore already contribute our thoughts and ideas as early as during the design process of a product.

Our approach to rapid tooling keeps a close eye on all the possibilities of 3D printing – from resource-saving lightweight construction to the functional integration of elements such as conformal cooling channels and right through to specification-dependent material recommendations, finishing options and the final assembly of groups of components. FKM is open to your ideas and is passionate about making them a reality with LPBF solutions. The active involvement of FKM reduces the development risk and secures further investment steps.

“At FKM, we offer rapid tooling with state-of-the-art solutions that not only work but are also cost-effective.”

At FKM, the process of rapid tooling in 3D printing takes place in four steps –
from the initial consultation to the finished tool.

1. Erstgespräch

Das Erstgespräch legt die technische Grundlage für Ihre Projektidee. Sie erhalten umfassende Informationen zur passenden Materialwahl, zur Umsetzbarkeit sowie bei Bedarf auch zum Thema konturnahe Kühlung.

2. Simulation am PC

Stehen die Rahmenbedingungen, simulieren wir am PC, wofür das Werkzeug genutzt werden soll und wo Optimierungen notwendig und umsetzbar sind, beispielsweise über eine konturnahe Kühlung. Sind alle Parameter festgesetzt, werten wir gemeinsam mit Ihnen die Simulation aus. Durch die Simulationen im Vorfeld des 3D-Drucks können wir den optimalen Verlauf der Temperierkanäle gewährleisten.

3. Erstellen der 3D-Daten im CAD-Programm

Sind Sie mit der Simulation zufrieden, erstellen wir auf ihrer Basis die 3D-Druckdaten für die Werkzeuge und Werkzeugeinsätze mitsamt der Kühlstrukturen. Bevor die Komponente in den Druck geht, prüfen Sie die digitalen Druckdaten final und geben Ihr Go! für den 3D Druck.

4. Fertigung des Werkzeugs

Mittels LPBF-Verfahren fertigen wir nun das Werkzeug entlang der Druckdaten.

Quest for innovation

Conformal temperature control:
How we optimise your production

Together with our partner iQtemp, a specialist in conformal temperature control in rapid tooling, we have perfected the cooling process in additively manufactured tools and moulds.

“It’s amazing how cold the component is when it falls out of the tool.”

We receive this feedback from our customers all the time. Thanks to our exact simulations and additive manufacturing process, we can guarantee the optimal flow of the temperature control channels in injection-moulding and die-casting tools.

The metal pressure powder is fused at points where hard steel will later be used, and the powder is retained where the cavities for the temperature control channels will be created. This means that no subsequent processing of the tool is necessary because the temperature control channels are already integrated directly into the tool during the 3D manufacturing process.

Advantages of conformal cooling from FKM & iQtemp

Diversity. Six metals.

What advantages must the material have for your application? Tensile strength, fracture resistance, temperature resistance, bending flexibility or lightness?

Whatever components you need to produce, FKM has the right material to meet every requirement. Put your trust in our experience – together we will find the perfect material.

Overview

Metals

Our comprehensive portfolio of highly developed metal materials has proven itself in daily practice. The modern metal powders ensure the desired product properties and make the reproductions reliably repeatable.

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