ORNL 3D Prints Steel Mold for Boeing Aircraft Work

Oak Ridge National Laboratory and Boeing produced a steel Stamp Form Die mold using wire-arc additive manufacturing (WAAM). The tool stands 6 feet tall, weighs close to 2 tons and took eight weeks to print; Boeing will use it for NASA's HiCAM composite aircraft program.

• Mold is 6 feet tall, 4 feet wide and weighs close to 2 tons; printing took 8 weeks
• Combines mild steel for structure and stainless steel for the working surface
• Printed curved internal channels replace straight drilled heating and cooling holes
• After 32 simulation iterations the print landed within millimeters of target shape