UNIVERSITY DEPARTMENT OF ANNA UNIVERSITY

DEPARTMENT OF PRODUCTION TECHNOLOGY

Madras Institute of Technology Campus
Chennai- 600 044
PROJECT PR571 FIRST REVIEW

FABRICATION OF TOOLING FOR SHEET

METAL FORMING USING FDM PRINTING

PROJECT STUDENTS PROJECT GUIDES

Aravind MB, (2020507003) Mr. N. Arunagiri, Teaching Fellow

Ravivaram R, (2020507029) and and
Veera Lingesh Kumar P, (2020507046) Mr. K. Tamilarasan, Teaching Fellow

ARAVIND MB (2020507003) ,RAVIVARMA R (2020507029) and VEERA LINGESH KUMAR P (2020507046) :FABRICATION OF TOOLING FOR SHEET METAL FORMING USING
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Abstract:
• Sheet metal forming processes play a pivotal role in modern manufacturing, offering a versatile means to
shape intricate components with precision. However, the production of forming dies, traditionally
manufactured from conventional tooling materials, for personalised production scenario often presents
challenges in terms of time, cost, and design limitations. In response to these challenges, this project
aims to revolutionize die manufacturing by leveraging advanced technologies and materials.

• Our project, titled “Fabrication of Tooling for Sheet Metal Forming Using FDM Printing," focuses on
the development of a composite die structure fabricated through Fused Deposition Modeling (FDM) 3D
printing. The die will feature a composite structure, with epoxy resin as the impregnation material,
offering enhanced durability and wear resistance similar to conventional die materials. To maximize
structural integrity and mechanical performance, the infill pattern within the die will be gyroidal in
nature, optimizing material distribution and strength.

• To further augment the die's resilience and longevity, we plan to coat the 3D-printed die with epoxy. This
epoxy coating will provide an additional layer of protection, reinforcing the die against deformation
during the rigorous sheet metal forming process. By combining FDM 3D printing technology, composite
materials, gyroidal infill patterns, and epoxy coating, our project aims to deliver a robust and cost-
effective solution for sheet metal forming dies.
ARAVIND MB (2020507003) ,RAVIVARMA R (2020507029) and VEERA LINGESH KUMAR P (2020507046) : FABRICATION OF TOOLING FOR SHEET METAL FORMING
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USING FDM PRINTING
LITERATURE SURVEY
Author Paper Title Journal Name Inference
Tondini et al. The Performance of 3D Printed Metals FDM printed tools can be used
Polymer Tools in Sheet Metal 2021, 11, 1256. https://doi.org/ to successfully form sheet metal
Forming 10.3390/met11081256 parts, but that the tool life is
limited.The authors also found
that the surface quality of the
formed parts is affected by the
printing parameters

Liu et al. Fused deposition modeling 3D
printing of polyamide-based
composites and its applications
Composites Communications
Volume 21, October 2020,
100413
The authors found that FDM
printed metal tools can be used
to successfully form sheet metal
parts with a longer tool life than
FDM printed polymer tools.
However, the authors also
found that the surface quality of
the formed parts is lower than
that of parts formed using
traditional machined tools.

ARAVIND MB (2020507003) ,RAVIVARMA R (2020507029) and VEERA LINGESH KUMAR P (2020507046) : FABRICATION OF TOOLING FOR SHEET METAL FORMING
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USING FDM PRINTING
LITERATURE SURVEY
Author
Peter Frohn-Sörensen, Michael
Geueke et.al. for flexible sheet metal drawing
Daniil Klimyuk , Mikhail
Serezhkin, Andrey Plokhikh
ARAVIND MB (2020507003) ,RAVIVARMA R (2020507029) and VEERA LINGESH KUMAR P (2020507046) : FABRICATION OF TOOLING FOR SHEET METAL
Paper Title
3D printed prototyping tools
Application of 3D printing in
sheet metal forming
FORMING USING FDM PRINTING
Journal Name
The International Journal of
Advanced Manufacturing
Technology (2021) 115:2623–
2637
Materials Today: Proceedings
38 (2021) 1579–1583
Inference
The authors found out that
FDM printed tools can bring
the cost of production down in
case of mass personalized
production. Various commonly
available material were tested
and PLA was found to be most
suitable for forming. The
method is most suitable for
serial unit production.
The main drawback of using
FDM printed rapid tool is
highlighted by author as low
proportional point of FDM
printed material. The
predictability of the
proportionality point is very
difficult.
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LITERATURE SURVEY
Author
Naotaka Nakamura
ARAVIND MB (2020507003) ,RAVIVARMA R (2020507029) and VEERA LINGESH KUMAR P (2020507046) : FABRICATION OF TOOLING FOR SHEET METAL FORMING USING
Paper Title
Bending of sheet metal
using plastic tools made
with 3d printer
FDM PRINTING
Journal Name
Procedia Manufacturing
15 (2018) 737–742
Inference
A combination of punch
and die were made of
plastic and sheet metal
bending was performed.
The springback effect was
same for all combination.
The dimensional accuracy
was best for metal punch
and metal die. The plastic
punch and die were
subject to deformation.
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PROBLEM DEFINITION

• Sheet metal forming processes are essential in manufacturing, and the use of FDM printed
tools offers the potential to reduce production costs, especially in mass personalized
production scenarios. However, the limited tool life and challenges related to surface
quality and material properties of FDM printed tools raise significant concerns.
Furthermore, the unpredictability of the proportionality point and the impact of tool
material (metal vs. plastic) on dimensional accuracy remain unclear. Therefore, the
problem to address in this project is to develop a reliable and cost-effective methodology
for fabricating FDM printed tools for sheet metal forming, optimizing tool design and
material selection to enhance tool life, surface quality, and dimensional accuracy, while
also addressing the challenges associated with the proportionality point

ARAVIND MB (2020507003) ,RAVIVARMA R (2020507029) and VEERA LINGESH KUMAR P (2020507046) : FABRICATION OF TOOLING FOR SHEET METAL FORMING USING
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OBJECTIVES OF THE PROJECT

• To imrpove strenght of die and punch by impregnating it with resin

matrix.
• Reduce the surface deformation of punch and die by coating the
material with reinforcement.

ARAVIND MB (2020507003) ,RAVIVARMA R (2020507029) and VEERA LINGESH KUMAR P (2020507046) : FABRICATION OF TOOLING FOR SHEET METAL FORMING USING
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Engineering systems

For the purpose of the sheet metal forming process we primarily require :
1) 3D Modeling and Slicer Software: It is used for the purpose of designing
the software and planning toolpath for printing.(Solidworks and Prusa Slicer)
2) FDM Printing Machine : It is used for manufacturing the die.(Ultimaker
S3)
3) Vacuum Chamber : It is used for the purpose of curing the resin poured in
the die without air bubbles.
4) Hydraulic Press : It is used for the purpose of punching the sheet metal
using the die.
5) Inspection Technique apparatus for the surface of the Die and Sheet Metal.

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Variables and Parameters

1) Slicer Software : The software can be used to slice a 3D model with various
types of infill.
2) Filament Material : The filament material is chosen majorly based on the
mechanical property favorable for the purpose of sheet metal forming.
3) Impregnating Material: The material should improve the characteristic of the
die and the material should be non reactive to the die material.(Epoxy+Fiberglass
Cloth;Epoxy + Kevlar fibers).
4) Curing and Waiting Time : PLA material is hygroscopic in nature making it
absorb moisture. The characteristics of the die may change with time.
5) Punching Cycles: The dimensional accuracy of the sheet metal formed may
change with the number of punch cycles.

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Existing Process/ Solutions:

There are several alternative processes and solutions for fabricating tooling for sheet metal
forming apart from 3D printing. Here are some of them:

1. CNC Machining:Traditional CNC (Computer Numerical Control) machining can be

used to fabricate sheet metal forming tooling from materials like steel or aluminum. While
it may be more time-consuming and expensive than 3D printing, CNC machining offers
high precision and can handle a wide range of materials.

2. Investment Casting: Investment casting, also known as lost-wax casting, can be used to
create tooling for sheet metal forming. A wax or 3D-printed pattern of the desired tool is
created and coated with a ceramic shell. The wax is melted out, leaving a cavity that is then
filled with molten metal. This method can produce complex and high-quality tooling.

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Existing Process/ Solutions(contd)

3. Electroforming: Electroforming is a process where a thin layer of metal is grown onto a

pattern or mold using an electrochemical deposition process. It can create highly detailed
and precise tooling for sheet metal forming. The resulting tool can be made from materials
like nickel, which is known for its durability.

4. Hydroforming: Hydroforming involves using high-pressure fluid to shape sheet metal

against a mold. While this is typically used for forming the final sheet metal parts, it can
also be employed to create the forming tooling itself. It is particularly useful for producing
complex shapes.

5. Additive Manufacturing with Metal:Instead of plastic-based 3D printing, metal-based

additive manufacturing processes like selective laser melting (SLM) or electron beam
melting (EBM) can be used to produce tooling from metal powders. These methods are
more expensive than plastic 3D printing but offer the advantage of using metals directly.
ARAVIND MB (2020507003) ,RAVIVARMA R (2020507029) and VEERA LINGESH KUMAR P (2020507046) : FABRICATION OF TOOLING FOR SHEET METAL FORMING USING
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Existing Process/ Solutions(contd)
6. Composite Tooling: Composite materials, such as carbon fiber reinforced composites, can
be used to create tooling. These materials are lightweight, durable, and can be shaped to
complex geometries. They are especially useful for low-volume production runs.

7. Machining from Forged Blanks: Instead of machining from solid blocks, you can start
with a pre-forged blank that has a rough shape resembling the desired tool. This can
significantly reduce machining time and material waste compared to starting from a solid
block.

8. Electro-Discharge Machining (EDM): EDM is a process where material is removed

using electrical discharges or sparks. It's commonly used for creating complex shapes in hard
metals that are difficult to machine with traditional methods.

ARAVIND MB (2020507003) ,RAVIVARMA R (2020507029) and VEERA LINGESH KUMAR P (2020507046) : FABRICATION OF TOOLING FOR SHEET METAL FORMING USING
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 Existing Process/ Solutions(contd)
9. Injection Molding: This process involves creating a mold (die) from a master
pattern. Molten material is then injected into the mold to create a final product. While
this is typically used for mass production, it can be applied in die-making.

10. Sand Casting: In sand casting, a pattern (which can be used to make a die) is
pressed into sand to create a mold. Molten metal is then poured into the mold, creating
the desired shape.

Apart From These Various advanced Machining Processes like Laser Cutting, Wire
EDM Etc is also there

ARAVIND MB (2020507003) ,RAVIVARMA R (2020507029) and VEERA LINGESH KUMAR P (2020507046) : FABRICATION OF TOOLING FOR SHEET METAL FORMING USING
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Comparison on Alternate Processes:
To compare and contrast the alternative processes with FDM (Fused Deposition Modeling)
printing for tooling fabrication, let's consider various aspects such as cost, speed, complexity,
material properties, and suitability for different scenarios.

1. Cost:
- FDM Printing: Generally, FDM printing is relatively cost-effective, especially for low to
medium production volumes.
-CNC Machining: CNC machining can be more expensive due to material costs, machine
time, and labor.
- Investment Casting: Investment casting can be cost-effective for high-precision tooling
but may have higher upfront costs.
ARAVIND MB (2020507003) ,RAVIVARMA R (2020507029) and VEERA LINGESH KUMAR P (2020507046) : FABRICATION OF TOOLING FOR SHEET METAL FORMING USING
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1.Cost(Contd):

- Electroforming: Electroforming can be expensive upfront due to the equipment and

process complexity.
- Additive Manufacturing with Metal: Metal-based additive manufacturing is
typically more expensive than FDM printing.
- Composite Tooling: Composite tooling can be cost-effective for lightweight and
durable tooling.
- Machining from Forged Blanks: This can be a cost-effective method, especially if
using pre-forged blanks.
- Rapid Tooling: Rapid tooling is often cost-effective for prototyping and short runs.
ARAVIND MB (2020507003) ,RAVIVARMA R (2020507029) and VEERA LINGESH KUMAR P (2020507046) : FABRICATION OF TOOLING FOR SHEET METAL FORMING USING
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 2. Speed:

- FDM Printing: FDM printing is relatively fast, especially for simple geometries.
- CNC Machining: CNC machining can be slower due to toolpath generation and
machining time.
- Investment Casting: Investment casting may have a longer lead time due to
pattern creation and casting.
- Electroforming: Electroforming can have a moderate lead time due to the
electrochemical deposition process.
- Hydroforming: Hydroforming can be relatively quick for forming tooling.

ARAVIND MB (2020507003) ,RAVIVARMA R (2020507029) and VEERA LINGESH KUMAR P (2020507046) : FABRICATION OF TOOLING FOR SHEET METAL FORMING USING
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 2.Speed(Contd)

- Additive Manufacturing with Metal: Metal-based additive manufacturing may

have longer lead times due to complex processes.
- Composite Tooling: Composite tooling can be fast for prototyping and short-run
production.
- Machining from Forged Blanks: Lead times can be shorter, especially if using
pre-forged blanks.
- Rapid Tooling: Rapid tooling is known for its quick turnaround for short-run
applications.

ARAVIND MB (2020507003) ,RAVIVARMA R (2020507029) and VEERA LINGESH KUMAR P (2020507046) : FABRICATION OF TOOLING FOR SHEET METAL FORMING USING
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 3. Complexity:
- FDM Printing: FDM printing excels at producing complex geometries.
- CNC Machining: CNC machining can handle complex shapes but may have limitations.
- Investment Casting: Investment casting can produce highly detailed tooling.
- Electroforming: Electroforming can create intricate tooling with high precision.
- Hydroforming: Hydroforming is suitable for complex forming operations.
- Additive Manufacturing with Metal: Metal-based additive manufacturing can handle
complex geometries.
- Composite Tooling: Composite materials can be molded into complex shapes.
- Machining from Forged Blanks: Complex shapes are feasible, especially if starting
from a pre-forged blank.
- Rapid Tooling: Rapid tooling is adaptable for complex prototypes and short-run tooling.
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ARAVIND MB (2020507003) ,RAVIVARMA R (2020507029) and VEERA LINGESH KUMAR P (2020507046) : FABRICATION OF TOOLING FOR SHEET METAL FORMING USING
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4. Material Properties:
- FDM Printing: Limited to plastics, which may not have the strength of metals.
- CNC Machining: Can use a wide range of materials, including high-strength metals.
- Investment Casting: Can use various metals for tooling with excellent material properties.
- Electroforming: Can create tooling with good material properties, especially in nickel.
- Hydroforming: Tooling can be made from various materials, depending on the application.
- Additive Manufacturing with Metal: Offers the benefits of metal strength and durability.
- Composite Tooling: Combines lightweight properties with good strength and durability.
- Machining from Forged Blanks: Materials can be chosen based on specific needs.
- Rapid Tooling: Material properties depend on the selected rapid tooling material.
Conclusion On Comparison: Our Main Motto is rapid tooling for low to medium production
volumes with complex geometries, for this FDM printing can be an excellent choice due to its
ARAVIND MB (2020507003) ,RAVIVARMA R (2020507029) and VEERA LINGESH KUMAR P (2020507046) :
cost-effectiveness and speed. FABRICATION OF TOOLING FOR SHEET METAL FORMING USING FDM PRINTING
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 METHODOLOGY
PROJECT METHODOLOGY
Literature Review

FDM Filament Impregnation Material to be

Infill Type
Material. Material embossed.

3D Designing of Die

Fabrication of Die
via FDM

Embossing the Sheet

Metal.

ARAVIND MB (2020507003) ,RAVIVARMA R (2020507029) and VEERA

Testing for Accuracy
LINGESH KUMAR P (2020507046) : FABRICATION OF TOOLING FOR 20
SHEET METAL FORMING USING FDM PRINTING
 Timeline chart
Work to be carried out Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7

Concept generation
Purchase of
components/materials
Fabrication & Testing
Report preparation

ARAVIND MB (2020507003) ,RAVIVARMA R (2020507029) and VEERA LINGESH KUMAR P (2020507046) : FABRICATION OF TOOLING FOR SHEET METAL FORMING USING
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 REFERENCES

• Peter Frohn-Sörensen, Michael Geueke , Tadele Belay Tuli, Christopher

Kuhnhen, Martin Manns,Bernd Engel - 3D printed prototyping tools for flexible
sheet metal drawing, The International Journal of Advanced Manufacturing
Technology (2021) 115:2623–2637.2)
• Daniil Klimyuk , Mikhail Serezhkin, Andrey Plokhikh - Application of 3D
printing in sheet metal forming, Materials Today: Proceedings 38 (2021) 1579–
1583.3)
• Naotaka Nakamura - Bending of sheet metal using plastic tools made with 3d
printer, Procedia Manufacturing 15 (2018) 737–742.4)
• JEMAL IDRIS ISMAIL, KAFEEL SANNI - Exploring the Possibilities of Sheet
Metal Forming Via Plastic-Based Additive Manufacturing Moulding, 2023

ARAVIND MB (2020507003) ,RAVIVARMA R (2020507029) and VEERA LINGESH KUMAR P (2020507046) : FABRICATION OF TOOLING FOR SHEET METAL FORMING USING
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 REFERENCES

• Tondini, F.; Basso, A.;Arinbjarnar, U.; Nielsen, C.V. The Performance of 3D

Printed Polymer Tools in Sheet Metal Forming. Metals 2021, 11, 1256. https://
doi.org/10.3390/met11081256 .
• Exploring the Possibilities of Sheet Metal FormingVia Plastic-Based Additive
Manufacturing Mouldingcarried out at KTH IIP Laboratory, Stockholm, Sweden.
Author: JEMAL IDRIS ISMAILKAFEEL SANNI.
• Fused deposition modeling 3D printing of polyamide-based composites and its
applications Xu Zahang, Wei Fan, Tianxi Liu Composites Communications
Volume 21, October 2020, 100413.

ARAVIND MB (2020507003) ,RAVIVARMA R (2020507029) and VEERA LINGESH KUMAR P (2020507046) : FABRICATION OF TOOLING FOR SHEET METAL FORMING USING
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