Additive Manufacturing for complex die casting tools: Scalable process for large aluminum components successfully demonstrated

The Fraunhofer ILT and MacLean-Fogg have jointly produced a complex die casting tool inlay using Laser Powder Bed Fusion (PBF-LB/M). The specially developed L-40 tool steel enables the additive manufacturing of heavily loaded, large-volume tools for the first time and thus the implementation of conformal cooling. Initial results from smaller tools, which Toyota is already using in series production, indicate a significantly longer service life for the additively manufactured tools. In the current project, a hybrid, large-volume tool was created for the transmission housing of the Toyota Yaris Hybrid. The combined process with conventional preforms plus additively manufactured structures shortens the production time, reduces costs and allows a high number of variants on a combined tool platform.