Manufacturing costs reduction due to stronger but cheaper composite tool

Continuous fiber reinforced die for sheet metal forming is 75% cheaper but more durable than its counterpart from high performance plastic, Ultem.

Helicopter factory needs a mold for sheet metal forming. The die must bear 400 bar pressure.

Plywood's - traditional material - lifespan is too short. The metal die would work longer but costs significantly more. The best option to extend a lifespan and reduce costs is to print a composite die.

Three dies from different materials were printed: the first from high performance plastic, Ultem; the other two: from PETG reinforced with Anisoprint reinforcing materials: Composite Carbon Fiber and Composite Basalt Fiber.

Anisoprinting reduces costs 2–4 times while raising durability. Moreover, anisoprinted tools have the potential to be even stronger if needed:

Composite lattice (isogrid) infill Composite lattice (isogrid) infill

In the part, the required durability (400 bar) is reached only by 30% of infill density. Since anisoprinting allows varying fiber direction, fiber volume ratio and material density, it's possible to print continuous fiber reinforced lattice structures. That means using minimum material for the required strength. It leads to lower weight, production time and price of the part.