Investigation of Digital Light Processing-Based 3D Printing for Optimized Tooling in Automotive and Electronics Sheet Metal Forming
This study addresses the emerging need for efficient and cost-effective solutions in low-volume production by exploring the mechanical performance and industrial feasibility of cutting tools that are fabricated using stereolithography apparatus (SLA) technology. SLA’s high-resolution capabilities ma...
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| Format: | Article |
| Language: | English |
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MDPI AG
2025-01-01
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| Series: | Journal of Manufacturing and Materials Processing |
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| Online Access: | https://www.mdpi.com/2504-4494/9/1/25 |
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| author | Szabolcs Szalai Brigitta Fruzsina Szívós Vivien Nemes György Szabó Dmytro Kurhan Mykola Sysyn Szabolcs Fischer |
| author_facet | Szabolcs Szalai Brigitta Fruzsina Szívós Vivien Nemes György Szabó Dmytro Kurhan Mykola Sysyn Szabolcs Fischer |
| author_sort | Szabolcs Szalai |
| collection | DOAJ |
| description | This study addresses the emerging need for efficient and cost-effective solutions in low-volume production by exploring the mechanical performance and industrial feasibility of cutting tools that are fabricated using stereolithography apparatus (SLA) technology. SLA’s high-resolution capabilities make it suitable for creating precise cutting dies, which were tested on aluminum sheets (Al99.5, 0.3 mm, and AlMg3, 1.0 mm) under a 60-ton hydraulic press. Measurements using digital image correlation (DIC) revealed minimal wear and deformation, with tolerances consistently within IT 0.1 mm. The results demonstrated that SLA-printed tools perform comparably to conventional metal tools in cutting and bending operations, achieving similar surface quality and edge precision while significantly reducing the production time and cost. Despite some limitations in wear resistance, the findings highlight SLA technology’s potential for rapid prototyping and short-run manufacturing in the automotive and electronics sectors. This research fills a critical gap in understanding SLA-based tooling applications, offering insights into process optimization to enhance tool durability and broaden material compatibility. These advancements position SLA technology as a transformative tool-making technology for flexible manufacturing. |
| format | Article |
| id | doaj-art-c5e8b5b9f24d466a9461fcd2b74e6332 |
| institution | Kabale University |
| issn | 2504-4494 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj-art-c5e8b5b9f24d466a9461fcd2b74e63322025-01-24T13:36:29ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942025-01-01912510.3390/jmmp9010025Investigation of Digital Light Processing-Based 3D Printing for Optimized Tooling in Automotive and Electronics Sheet Metal FormingSzabolcs Szalai0Brigitta Fruzsina Szívós1Vivien Nemes2György Szabó3Dmytro Kurhan4Mykola Sysyn5Szabolcs Fischer6Central Campus Győr, Széchenyi István University, H-9026 Győr, HungaryCentral Campus Győr, Széchenyi István University, H-9026 Győr, HungaryCentral Campus Győr, Széchenyi István University, H-9026 Győr, HungaryCentral Campus Győr, Széchenyi István University, H-9026 Győr, HungaryDepartment of Transport Infrastructure, Ukrainian State University of Science and Technologies, UA-49005 Dnipro, UkraineDepartment of Planning and Design of Railway Infrastructure, Technical University Dresden, D-01069 Dresden, GermanyCentral Campus Győr, Széchenyi István University, H-9026 Győr, HungaryThis study addresses the emerging need for efficient and cost-effective solutions in low-volume production by exploring the mechanical performance and industrial feasibility of cutting tools that are fabricated using stereolithography apparatus (SLA) technology. SLA’s high-resolution capabilities make it suitable for creating precise cutting dies, which were tested on aluminum sheets (Al99.5, 0.3 mm, and AlMg3, 1.0 mm) under a 60-ton hydraulic press. Measurements using digital image correlation (DIC) revealed minimal wear and deformation, with tolerances consistently within IT 0.1 mm. The results demonstrated that SLA-printed tools perform comparably to conventional metal tools in cutting and bending operations, achieving similar surface quality and edge precision while significantly reducing the production time and cost. Despite some limitations in wear resistance, the findings highlight SLA technology’s potential for rapid prototyping and short-run manufacturing in the automotive and electronics sectors. This research fills a critical gap in understanding SLA-based tooling applications, offering insights into process optimization to enhance tool durability and broaden material compatibility. These advancements position SLA technology as a transformative tool-making technology for flexible manufacturing.https://www.mdpi.com/2504-4494/9/1/253D printingSLArapid prototype3D scanningoptimizationpart-off die |
| spellingShingle | Szabolcs Szalai Brigitta Fruzsina Szívós Vivien Nemes György Szabó Dmytro Kurhan Mykola Sysyn Szabolcs Fischer Investigation of Digital Light Processing-Based 3D Printing for Optimized Tooling in Automotive and Electronics Sheet Metal Forming Journal of Manufacturing and Materials Processing 3D printing SLA rapid prototype 3D scanning optimization part-off die |
| title | Investigation of Digital Light Processing-Based 3D Printing for Optimized Tooling in Automotive and Electronics Sheet Metal Forming |
| title_full | Investigation of Digital Light Processing-Based 3D Printing for Optimized Tooling in Automotive and Electronics Sheet Metal Forming |
| title_fullStr | Investigation of Digital Light Processing-Based 3D Printing for Optimized Tooling in Automotive and Electronics Sheet Metal Forming |
| title_full_unstemmed | Investigation of Digital Light Processing-Based 3D Printing for Optimized Tooling in Automotive and Electronics Sheet Metal Forming |
| title_short | Investigation of Digital Light Processing-Based 3D Printing for Optimized Tooling in Automotive and Electronics Sheet Metal Forming |
| title_sort | investigation of digital light processing based 3d printing for optimized tooling in automotive and electronics sheet metal forming |
| topic | 3D printing SLA rapid prototype 3D scanning optimization part-off die |
| url | https://www.mdpi.com/2504-4494/9/1/25 |
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