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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

  • Faster tool and mould construction: With 3D printing for rapid tooling, tool components and inserts, for example for injection moulding machines, can be created much easier and faster than with conventional manufacturing methods. As a result, companies are able to react to changing customer needs more quickly and adapt products at short notice if necessary.
  • Cost savings: Rapid tooling is usually more cost-effective than traditional tooling because 3D printers are capable of creating complex shapes and tools with minimal use of materials and resources. Since the process is very precise, there is also less waste and fewer rejects.
  • Flexibility: Rapid tooling makes manufacturing processes more flexible because changes to moulds and tools can be made quickly and easily. A new design is simply loaded into the 3D printer, and the new tool is printed within a few hours.
  • Design freedom: Thanks to the three-dimensional layering process, tools with complex geometric structures and cavities can be created without any problems or additional effort. It is also possible to integrate optimised and conformal cooling channels regardless of the geometry. During operation, such channels significantly improve the cooling performance of the tool, which in turn also has a positive effect on reducing cycle times.
  • Lower risk: Rapid tooling can lower investment risks because companies do not have to commission the production of expensive tools and moulds before knowing whether their products will be successful. Instead, they can create tool prototypes quickly and cost-effectively to test and optimise the manufacturing process.

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. Initial consultation

The initial consultation lays the technical foundation for your project idea. You will receive comprehensive information on the right choice of material, feasibility and, if required, on the subject of conformal cooling.

2. Simulation on PC

Once the framework conditions have been established, we simulate on the PC what the tool is to be used for and where optimisations are necessary and can be implemented, for example via conformal cooling. Once all the parameters have been determined, we analyse the simulation together with you. Thanks to the simulations prior to 3D printing, we can ensure that the temperature control channels are optimised.

3. Creating the 3D data in the CAD programme

Once you are satisfied with the simulation, we use it as the basis for creating the 3D print data for the moulds and mould inserts, including the cooling structures. Before the component goes to print, you finalise the digital print data and give your go! for 3D printing.

4. Production of the tool

Using the LPBF process, we now manufacture the mould along the print data.

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

  • Uniform flow rate of the cooling water
  • Very rapid, homogeneous cooling of the component
  • Cost-efficient integration into the 3D printing process

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.

Learn more
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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