Boeing and ORNL Develop Giant 3D Printed Mold for Thermoplastic Aircraft Production

A massive Stamp Form Die (SFD) mold, measuring 6 feet tall and 4 feet wide, has been developed through a partnership between Oak Ridge National Laboratory (ORNL) and Boeing. The SFD is used to cut or shape materials in the production of thermoplastic composite aircraft.

The mold was printed using wire-arc additive manufacturing (WAAM), a process that allows for the creation of complex geometries with multiple materials. Boeing utilized a network of American small and large businesses to execute the project, applying cutting-edge technology and engineering expertise to overcome technical challenges.

The SFD will be used by Boeing to contribute to NASA's Hi-Rate Composite Aircraft Manufacturing (HiCAM) project, which aims to increase production rates and reduce aircraft weight to improve fuel efficiency. The mold was designed with a combination of mild steel for strength and stiffness, and stainless steel for corrosion resistance.

The team at ORNL used computer simulations to refine the design and compensate for warping during the printing process, resulting in a mold that was within a few millimeters of its intended shape.