Large-scale additive manufacturing is well-suited for creating complex metal molds
That's according to work done at ORNL's Manufacturing Demonstration Facility in collaboration with IACMI–The Composites Institute.
Recent advancements at Oak Ridge National Laboratory (ORNL) 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 (MDF), 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 percent 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 percent.
Additive manufacturing also allows engineers to produce more complex mold geometries, such as internal heating channels, that would be difficult to achieve using conventional machining.
“The more complex the shape, the more valuable additive manufacturing becomes,” Nycz said.
The research team partnered with Collaborative Composites Solutions, operator of IACMI–The Composites Institute, to put the concept to the test. They chose to 3D print a large battery enclosure mold, complete with intricate internal features.
Like what you've read?
Forward to a friend!