Innovative 3D-Printed Tooling Solution Revolutionizes Toyota Europe's Manufacturing
Revolutionizing Automotive Manufacturing with 3D Printing
In an extraordinary leap for automotive manufacturing, MacLean-Fogg Company (MFC) in collaboration with the Fraunhofer Institute for Laser Technology ILT has achieved a new milestone by creating the world’s largest 3D-printed die casting tooling insert. This cutting-edge tool, weighing 156 kg (350 lbs), has been developed specifically for Toyota Europe's Yaris hybrid transmission housing.
Unprecedented Scale and Technology
The advent of this 3D-printed tooling solution signifies a remarkable advancement in the additive manufacturing sector within the automotive industry. This conformally cooled insert was realized through the utilization of Fraunhofer ILT's advanced gantry-type, multi-laser Laser Powder Bed Fusion (LPBF) system, combined with MacLean-Fogg’s proprietary L-40 tool steel powder. This hybrid manufacturing approach has been tailored to meet Toyota's cost expectations while ensuring the highest performance standards for automotive applications.
Dr. Magdalena Coventry and Dr. Andrew Willett from Toyota Europe expressed their enthusiasm, stating, "Gantry printing with L-40 tool steel powder material is a promising avenue towards scalable additive manufacturing, offering opportunities to reduce lead times and enhance manufacturing responsiveness, all while maintaining world-class insert performance."
Superior Material Properties
MacLean-Fogg’s L-40 powder is engineered for the LPBF process, boasting high hardness and toughness. This reduces the likelihood of crack formation and propagation during the printing process, even under moderate pre-heat temperatures. The L-40 material also mitigates the need for extensive post-build heat treatment, thus accelerating the overall production cycle. The benefits of this innovative product extend beyond mere performance:
- - Enhanced Durability: The lifespan of the L-40 tooling insert is approximately double that of conventional aluminum die-casting inserts.
- - Lower Maintenance Needs: Tooling maintenance requirements are significantly decreased, optimizing production efficiency.
- - Sustainability: This material is environmentally friendly, containing no cobalt and minimal nickel content.
Challenges Overcome in Development
The project posed considerable challenges, particularly in scaling up the manufacturing process. Dr. Harald Lemke, Director of Product Development at MacLean-Fogg, noted, "Toyota's request to leverage L-40 for large-format tooling inserts pushed us to confront challenges like ensuring consistent gas flow as build sizes increased."
To meet these demands, Fraunhofer ILT employed a five-laser LPBF system, capable of processing parts larger than 50 cm and reaching chamber temperatures of up to 200°C. Dr. Niklas Prätzsch from Fraunhofer emphasized that these evolved systems are crucial for quality assurance in large-scale additive manufacturing, allowing production to occur at lower temperatures without sacrificing quality.
Future Prospects
The successful implementation of this technology is not the endpoint but a launching pad for new innovations. Fraunhofer ILT and MacLean-Fogg envision the extension of this groundbreaking technology into structural die casting and inserts for giga-casting tools. This aligns with the automotive industry's broader trend towards lightweighting, shorter development times, and enhancing supply chain resilience.
For those eager to learn more, the innovation will be presented at prominent industry events including the NADCA Die Casting Congress on October 7 in Milwaukee, USA, and at Formnext 2025 from November 18 to 21 in Frankfurt, Germany.
About MacLean-Fogg and Fraunhofer ILT
MacLean-Fogg Company is a globally recognized entity within the automotive and industrial sectors, known for its high-performance fasteners, components, and tooling solutions. With over 100 years of experience, the firm continues to lead in innovation and manufacturing quality. Likewise, the Fraunhofer Institute for Laser Technology ILT stands at the forefront of laser technology research, dedicated to evolving manufacturing processes and enhancing production efficiency across various industries.
For more information on MacLean-Fogg’s endeavors in additive manufacturing, visit www.macleanfogg.com/additive.
Topics Consumer Technology）
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