Additive Manufacturing: A New Path to Tools, Jigs and Fixtures

Tooling and fixturing applications obviously abound in manufacturing environments. Not well known: Many of these applications can benefit from the speed and cost savings inherent in additive manufacturing (AM). Tools, jigs and fixtures, whether made from plastics, composites or metals, in many cases, can be produced in a fraction of the time needed for machining or other traditional processes. Oftentimes metal is the material of choice due to the rigors of the task at hand. In other cases, nonmetals do the trick.

Top: A sliding case from LKAB Wassara, used for water-powered, down-the-hole hammers in drilling applications, features optimized water channels and reduced assembly needs, both courtesy of the AM process. Bottom: These AM high-precision cemented-carbide nozzles, used in mining applications, significantly reduce production lead time as compared to machining.

MetalForming editors have seen plenty of metal and nonmetal examples while attending various AM events this year, and received news on more. Here are but a few examples, designed to convince metalformers and fabricators to think in new ways about ever-present challenges.

AM Mined for Improved Drilling

At this year’s RAPID + TCT show, held in April in Fort Worth, TX, Sandvick displayed metal-AM tools produced via laser-bed processes, using its powder materials. Here, AM reduces assembly needs and creates channels within the tools to promote cooling and deliver coolants and lubricants to the workpiece.

For another mining application, high-precision nozzles from Varel are used to inject fluid across fixed cutter bits. The small cemented-carbide nozzles must withstand the extreme environment of underground hard-rock drilling as well as extreme hydraulic conditions.

The nozzles feature sophisticated hydrodynamic designs that optimize fluid flow for more efficient cooling and cleaning, leading to faster cutting and evacuation of drill cuttings and optimized hydraulic energy usage, according to Sandvick officials. AM—in this case via binder jetting—enables more rapid manufacturing and delivery of the nozzles, meaning less inventory needed. The nozzles previously were produced through traditional machining, a long process with long lead times. As a result, Varel required high inventories to keep customers supplied. This no longer is the case, Varel officials claim, as thanks to AM, lead times have been cut by as much as 70 percent. Another plus: AM allows for customized nozzle options.