Recent advancements at the Department of Energy’s Oak Ridge National Laboratory show that 3D-printed metal molds offer a faster, more cost-effective and flexible approach to producing large composite components for mass-produced vehicles than traditional tooling methods.
The research, conducted at the Manufacturing Demonstration Facility, or MDF, at ORNL, confirms that large-scale additive manufacturing is well-suited for creating complex metal molds, with efficiencies that could accelerate the adoption of lightweight composite materials in the automotive sector.
“This kind of technology can help reindustrialize the U.S. and boost its competitiveness by creating smarter, faster ways to build essential tools,” said lead researcher Andrzej Nycz with ORNL’s Manufacturing Robotics and Controls group. “It brings us closer to an automated, intelligent production process.”
Traditionally, metal tools are made by subtracting material from large, forged steel blocks — a process that removes up to 98% of the original material, generates significant waste and often takes months due to supply chain delays. In contrast, additive manufacturing deposits metal layer by layer, using widely available welding wire as a feedstock and minimizing waste to about 10%.
This Oak Ridge National Laboratory news article "3D printing metal molds poised to accelerate US auto manufacturing" was originally found on https://www.ornl.gov/news
