Design and Additive Manufacturing of a Flat Form Tool

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The focus of this in-depth study is largely on the application of additive manufacturing in the creation of a flat form tool; an integral component utilized in several engineering applications. The study progresses with a holistic approach where each stage lends itself to the more broad-scope objective of reimagining the process of tool production through advancements in 3D printing technologies. Initially, the study embarks upon an in-depth analysis of the flat form tool, from both a constructional and analytical perspective. Essentially, this aspect lays the basis for the forthcoming design stages and the actual production methodologies. Furthermore, this study encircles the creation of CAD models for both the tool and the workpiece. The entire layout procedure enlists sophisticated modelling patterns tailored specifically to enhance precision and maximum functionality to develop models. Thus, paving the path for an efficient production process attuned to accuracy. Following the design phase is the actual operationalization of additive manufacturing of the tool. The Ultimaker 3, 3D printer is pressed into service, using PLA (Polylactic Acid) material, for manufacturing the tool. The Ultimaker Cura Slicer Software has been utilized to transform intricate digital blueprints into precise physical entities, with efficient material usage. Lastly, a finite element analysis (FEA) is performed on the produced tool to gauge its performance amidst operational situations. The results of this evaluation offer vital understanding of the tool’s mechanical idiosyncrasies, thereby aiding the ratification of design selections and corroborating functionalities along with resilience. Overall, this thesis proves conclusively that additive manufacturing holds viability and obvious benefits when it comes to producing tools tailored for unique requirements. Ultimate power of 3D printing in transforming tool production shouldn’t be neglected as it offers flexibility, waste minimization and heightened productivity. The study marks a potential ground breaker in its domain, revealing an all-encompassing mechanism to tool formation and manufacturing. By doing so, this study opens doors to future developments and potential advancements in additive manufacturing application in an extensive spectrum of industries.

Additive Manufacturing, Finite Element Analysis, 3D Printing, CAD Model, Flat Form Tool