Top 5 Benefits of Using FDM Tooling for Sheet Metal Forming
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9/26/2015 Top 5 Benefits of Using FDM Tooling for Sheet Metal Forming https://www.stratasysdirect.com/blog/fdmsheetmetalforming/ 1/8 StratasysDirect.com GET A QUOTE Top 5 Benefits of Using FDM Tooling for Sheet Metal Forming Written on September 22, 2014 Sheet metal forming is a fundamental process in the metalworking that’s generally used for low-volume production applications. It has been employed in aerospace production lines for many years to create various airframe and engine components. The automotive industry metal forms engine cradles, suspension components,
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Transcript of Top 5 Benefits of Using FDM Tooling for Sheet Metal Forming
9/26/2015 Top 5 Benefits of Using FDM Tooling for Sheet Metal Forming
https://www.stratasysdirect.com/blog/fdmsheetmetalforming/ 1/8
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Top 5 Benefits of Using FDM Tooling forSheet Metal Forming
Written on September 22, 2014
Sheet metal forming is a fundamental process in the metalworking that’s generally used for low-volume
production applications. It has been employed in aerospace production lines for many years to create various
airframe and engine components. The automotive industry metal forms engine cradles, suspension components,
9/26/2015 Top 5 Benefits of Using FDM Tooling for Sheet Metal Forming
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radiator and instrument panel support beams and engine components. And the military will often produce one-off
replacements for the repair of damaged vehicles and aircraft using metal forming.
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Hydroforming is one of the most cost effective methods of sheet metal forming, primarily used in the automotive industry. Fluid
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pressure forces metal, such as aluminum, brass, alloy steel and stainless steel, directly over the die through a diaphragm. The
other common method is rubber pad forming in which a ram forces an elastomeric or urethane pad to deform as it presses the
metal using non-isotropic forces. You’ll often see rubber pad pressing in aerospace production for shallow parts fewer than 4
inches high.
Hydroforming and rubber pad pressing dies or form tools are traditionally CNC machined. But companies have started looking for
alternative die manufacturing methods due to shortages of skilled labor, long lead times due to backlog and the high cost of raw
materials. Fused Deposition Modeling (FDM) is an alternative method alleviating these challenges and helping companies move
from tool design to production in as little as a week. In metal forming tests, FDM tools lasted hundreds of cycles showing little to
no signs of wear.
Switching to FDM tools requires little change to current practices and procedures and offers significant benefits, including:
Reduced lead time & costsDepending on the geometry, FDM tools can be completed in less than 24 hours. Stratasys customers saw die cost reductions of
50 to 70 percent and lead time reductions of 60 to 80 percent when compared to traditional CNC machining.
Design flexibilitySince FDM builds parts layer by layer, from the ground up, there is virtually no limit to die geometry. Organically-shaped dies can
create complex metal parts for improved functionality and better part performance.
Natural porosity & lubricity
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The natural porosity between layers of FDM parts lends itself well to pulling the material close to the die and reducing trapped air
pockets. Also, FDM thermoplastics typically implemented for die manufacturing, like ULTEM 9085 and polycarbonate (PC), do not
adhere to metals so there’s no need to lubricate metal sheet blanks.
Coordinated tool familySince FDM builds parts from a digital CAD file, creating repeatable form tools without secondary processes or making functional
updates is simple. The digital aspect also gives you the flexibility to build spare dies on demand, freeing up storage space and
decreasing inventory costs.
Ergonomic factorsThermoplastic dies are generally lighter than traditionally manufactured dies made out of metals. With the design freedom you
gain from FDM, you also can design weight out of the part without sacrificing durability or integrity. This makes dies more
ergonomic than traditional tooling, resulting in improved safety for tool handlers and machine operators.
Follow the design guidelines below to take full advantage of FDM for sheet metal tooling.
Design Guidelines for FDM Sheet Metal Tools
Hydroforming Up to 10,000 psi (69MPa)
Rubber Pad Press 1,000 ton press up to 3 inches (76.2mm)
Cycles 400 – 600 cycles with no signs of wear
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Compatible metals Aluminum alloys, steels, stainless steels, titanium, Inconel
Sheet thicknesses 0.016in to 0.100in (0.41mm to 2.54mm)
FDM MaterialsABS: 3,000 psiPC: 7,000 psi
ULTEM: 10,000 psi
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