Direct Rapid Tooling for Complex Geometrical Components Using Direct Metal Laser Sintering Process

Rapid Prototyping (RP) generally refers to techniques that produce 3D prototypes by gradual addition of solid material layer by layer, differing fundamentally from material removal conventional manufacturing techniques. RP is emerging as a powerful tool in product development process. Rapid Tooling (RT) is an offshoot of RP process, which enables to make batch quantity production of components that could be used for functional testing or directly in the product assembly. Several RP processes are available, out of which Direct Metal Laser Sintering (DMLS) process is chosen for Direct Rapid Tooling (DRT) development. The Direct Rapid Tooling can be developed for injection moulding, investment casting, die casting and forming tool applications. This could also be used for several other manufacturing requirements. This paper deals with the production of forming tools with complex 3D surfaces using DMLS technology. The forming tools developed were successfully used for producing sheet metal aluminum components to the required geometrical accuracies for Aerospace applications.