Vooruitgang in laserpoederbedfusie voor de productie van matrijzen

As manufacturing moves deeper into the digital age, Additive Manufacturing (AM) stands at the forefront, promising an unprecedented combination of flexibility and data-driven customization. This thesis explores the potential of Laser Powder Bed Fusion (LPBF), a powder-based metal AM technology, to advance Direct Metal Tooling (DMT), particularly for injection and extrusion molding applications. Focusing on the critical aspects of topology optimization, advanced quality control, material selection, and optimized processing strategies, this work provides a blueprint for integrating LPBF into the industrial tooling sector. The study begins by addressing the paradigm shift in tooling design facilitated by AM. Topology optimization and design for additive manufacturing allow for the creation of mold structures that were previously impossible with traditional manufacturing methods. Using LPBF, complex geometries incorporating conformal cooling channels and organic freeform shapes were fabricated, demonstrating improved material efficiency and enhanced cooling performance. To bridge LPBF with conventional manufacturing, hybrid mold designs were as well developed, combining LPBF-built inserts with traditionally machined bases. These examples lay the groundwork for industrially relevant applications in injection and extrusion molding, highlighting the feasibility of producing intricate and durable tooling solutions via DMT. Subsequently, the research focuses on the internal quality of DMT components, which is critical for tool functionality and durability. Through industrial computed tomography, non-destructive testing was employed to analyze defect formation, revealing key correlations between LPBF process parameters and surface quality in internal channels and bores. These findings help defining design guidelines to enhance the reliability and performance of LPBF-fabricated tooling. Surface quality was also investigated by analyzing the properties of raw LPBF powders and their impact on final part quality. The use of engineered finer particle size distributions of M300 tool steel powders significantly reduced surface roughness and enabled near-polished finishes, especially on top surfaces. Advanced LPBF strategies, such as reduced layer thicknesses and in-situ remelting, further facilitated the production of fine surface features, presenting new opportunities for cost-effective mold surface functionalization. In pursuit of productivity, the research concludes by introducing the novel M789 maraging steel material and a high speed LPBF methodology. With thicker layer heights and a hull-bulk scanning strategy, production rates can be almost doubled compared to industry standards without significant loss in part relative density and overall quality. The findings of this thesis underscore the potential of LPBF when supported by tailored materials, optimized designs and fabrication strategies, together with advanced quality control techniques. However, achieving the full industrial potential of DMT requires continued innovation in as-built precision, automation, and predictive analytics. Hence, this work provides a solid foundation, lighting the path for future advancements that will make LPBF for direct metal tooling applications truly practical for the evolving demands of the modern manufacturing industry.