PTG evaluated FDM hydroforming form tools as an alternative to traditional form tools to produce one–off components to replace damaged or corroded sections of an aircraft frame. The corroded frame was digitally scanned and a CAD model of the repaired part and desired tool stream was created. A family of the tools including form tool, trim tool and drill tool were then manufactured with the Stratasys Fortus production system. In working with PTG on a variety of form tools, it has been demonstrated that FDM tools can see up to a 70% cost savings and as much as 80% cycle time savings compared to outsourced metal CNC tool fabrication.
“We were not familiar with FDM or the thermoplastic materials that are used in the process,” said Scott Pryer, President of PTG. “But after using FDM tools in our hydro forming presses, we are quite impressed. The FDM dies were produced in hours as opposed to the days that are normally required. These tools withstood up to 10,000 psi of pressure time after time. We believe that FDM tooling is a good option when time or traditional tooling methods are not practical. Since the tool building time–frame is greatly reduced, it will make part development easier. Tool designs can be tested, modified and retested quickly and easily.”
“Along with building the form tool, FDM has proved its value in making other accessories used in our process such as trim tools, drill tools, forming aids, etc,” Pryer added. “When forming down into blind recesses we typically have to use a vent hole to allow trapped air to escape. The FDM tooling is constructed in a way that it can vent trapped air without a vent hole. The plastic material also provides a surface lubricity that, in many cases, will eliminate the need for lubricant.”
How Did FDM Compare to Traditional Tooling Methods for Pryer?
Method | Cost | Time |
---|---|---|
CNC Machining | $1,500 | 5 days |
FDM Tooling | $450 | 1 day |
SAVINGS | $1,050 (70%) | 4 days (80%) |