Abstract

Additive manufacturing (AM) for large volume parts is a rising technology with the potential to reduce the fabrication costs and lead times for components. It has practical applications in multiple industrial fields. AM technology can be instrumental in producing large pieces with complex geometries, especially for tooling and ancillary equipment. Despite these advantages, several technological aspects limit the use of AM for massive manufacturing.

One of the limitations is the need to maintain the part and the working area at an elevated temperature using heating systems. Another critical limitation is the size of the 3D printing system, limiting the size of the components that can be produced using this technology and imposing some restrictions regarding the components’ geometry and thickness.

Research has been carried out to solve these primary issues, and specific solutions have been developed and matured. The solution shown on this article comprises:

1. A system that can alter the required temperature locally without using a heated working environment

2. A moving base that supports the part during the manufacturing process eliminates the part dimension’s limits, allowing for the manufacture of large -“infinite”- parts

3. The material applying process design allows depositing the material increased flexibility and perfect control of the thickness and layer overlap.

These new technologies have been tested extensively by manufacturing and testing large industrial molds obtaining excellent results. The fields of application of this technology are limitless. The principal industries that can benefit from immediate uses are the aerospace, wind energy, naval, and railway sectors. This technology will revolutionize the mold manufacturing industry, allowing the curing mold manufacturers to produce large curing molds at a low cost and shorter delivery times.