"This involves processes for turning with a lubricoolant attachment or for narrow tools where no internal cooling can be applied conventionally," reports Dr. Matthias Luik, Head of Research and Development at Paul Horn. A current product with a 3D printed component from the tool specialists in Tübingen is the lubricoolant distribution disk for a friction tool. With additive manufacturing (AM), there are a few special features to consider. "Due to the subsequent machining of the functional surfaces, appropriate structures must be created with which the workpieces can be clamped. In addition, residual stresses that lead to distortion of the components must be taken into account. The component position in the working area is particularly important here," says Dr. Luik.

Due to the variable application possibilities of additive manufacturing, it will be possible to produce more and more parts in an economically interesting way in the future. In order to keep machining work to a minimum, a hybrid design will prove advantageous in many cases, in which conventionally manufactured elements are combined with additively manufactured components.

In order to achieve optimum results in additive manufacturing, it is important to consider the entire process chain from the outset. The design is no longer based on a metal block, but on the function of the component. "In the field of machining, tool cooling is currently of interest," says Jürgen Förster, Member of the Management Board at AMF Andreas Maier in Fellbach. 3D printing allows the installation of conformal cooling channels, even for very small cutting, casting and injection molding tools. The integration of optimized cooling channels in the tools ensures faster cooling of the workpieces and thus brings enormous time savings.

In the field of machines and technology, innovations and networks of companies, research institutes and associations are driving development and the exchange of experience. "Series production and a holistic approach to processes play a central role here," reports Förster. "We entered into open communication at an early stage in order to optimize and standardize the various process steps from a clamping technology perspective. Our zero-point clamping system offers the best standardized interface for both the printing process and the entire post-processing."

In his opinion, there will be major growth in the future, particularly in metal 3D printing. After a phase of "trial and error", the desire for process reliability and automation is now coming to the fore. "As a solution provider, we already offer production-ready products that optimize the entire process and make it more economical," says Förster.

According to VDW / ag