Boeing, ORNL Collaborate on Massive 3D-Printed Steel Mold

Researchers at Oak Ridge National Laboratory (ORNL) and Boeing have spent eight weeks 3D-printing a massive steel mold measuring 6 feet tall, weighing nearly 2 tons. The tool is designed for manufacturing thermoplastic composite aircraft components as part of NASA's Hi-Rate Composite Aircraft Manufacturing (HiCAM) project.

The team used a process called wire-arc additive manufacturing (WAAM), which involves building a structure layer by layer using a robotic arm and welding torch. This approach allowed them to combine multiple types of metal, including mild steel for structural regions and stainless steel for corrosion resistance and dimensional stability.

To overcome the challenge of warping, the researchers used computer simulations to predict and compensate for the distortion that could occur during printing. After completing the mold, they sent it to Baker Industries in Michigan for further fabrication work.