Optimization of 3D Printed Rapid Prototype Deep Drawing Tools for Automotive and Railway Sheet Material Testing

Abstract

The main objective of this research is to identify optimal printing strategies and PLA (polylactic acid) filament materials to produce rapid prototype deep drawing tools. Additive 3D printing technologies have been applied for a long time to produce tools, but the research is unique in that it uses conventional and various reinforced PLA materials with conventional FDM (Fused Deposition Modeling) printers. The advantage of this method is that PLA is easy to print and recycle and does not require expensive or special printers, this also gives the article its novelty. A further aim was to produce the tools using commercially available low-end printers. DX53D 0.8 mm thick body steel and AlMg3 2.5 mm thick sheet were the materials to be molded for the tests. The test tool was an Erichsen deep drawing punch. Tool wear was tested using the GOM ATOS measuring system, an optical coordinate measuring machine based on the DIC (Digital Image Correlation) principle, which is also popular in the automotive industry. The study aims to determine the 3D printing and material parameters that can safely produce a minimum batch of 100 parts.

Keywords

• 3D printing
• FDM
• advanced PLA
• deep drawing
• additive manufacturing
• rapid tooling