Additive manufacturing
In recent years, the additive manufacturing sector has experienced significant growth of an average of around 30 percent per year. This situation is essentially due to the increasing use of the technologies for so-called direct manufacturing, that is the additive manufacturing of end products [1]. While in the 1990s additive manufacturing methods were used almost exclusively to manufacture prototypes, the portion of the turnover due to direct manufacturing was already 33 percent by 2017. Along with the rapid availability of prototypes, the crucial advantages of the layer manufacturing method are in the attainable design freedom that makes it possible to manufacture products optimised for function, in the shortening of delivery chains for the supply of spare parts, in the possibilities for the customisation of products because the need for forming moulds is low in additive process chains, and also in the potential for reducing repair costs and times.
With a total market volume in 2017 of around US$ 7.3 billion, the additive manufacturing sector is still a niche sector. The annual growth rate for coming years determined by ten independent institutions is, however, 31 percent. Here it can be seen that this niche sector will be significant in future. It can be assumed, therefore, that additive manufacturing methods will gain cross-sector relevance as production technologies in the medium term.
Today particular attention is dedicated to the additive manufacturing of metal parts. The most widespread method used in industry is laser beam melting, which is also known by trade names such as Selective Laser Melting (SLM) or Direct Metal Laser Sintering (DMLS) for example. There exists a series of other methods for additively manufacturing metal parts, for instance electron beam melting, metal binder jetting, the extrusion methods, laser powder deposition welding, laser wire deposition welding or wire and arc-based additive manufacturing. Today the most relevant method for tool making is laser beam melting. According to a study by Ernst & Young, it can be assumed that the total market for this metal processing manufacturing method will become increasingly important in the coming years.
Motivation
Additive manufacturing methods are also used during the manufacture of precision tools. The manufacturing restrictions that cause limitations during the conventional production of tools, such as the need for machine clamping setups or the restriction to the specific geometries that are possible to manufacture, largely fall away with additive manufacturing. As such, greater design freedom is possible. The construction and design of the tools can be reconsidered and in this way lead to a new tool generation. There is potential above all in the improvement of the mechanical properties, the saving of material or mass due to lightweight design, and the possibility of optimising the cost-effectiveness and the functionality due to hybrid design.
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