ORNL and Boeing Unveil Massive Steel Mold Printed with WAAM

Boeing and Oak Ridge National Laboratory (ORNL) have successfully created a massive steel mold for aircraft production using wire-arc additive manufacturing (WAAM). The Stamp Form Die (SFD) mold, weighing nearly two tons, took eight weeks to print on ORNL's Arc-1 system. It measures 6 feet tall and 4 feet wide.

The project aimed to explore the possibility of using WAAM in producing large forming tools for thermoplastic composite part production. Boeing collaborated with a network of US businesses to carry out the work, which involved printing a tool that combines two alloys, mild steel for strength and stiffness, and stainless steel for corrosion resistance.

According to ORNL senior robotics engineer Andrzej Nycz, multi-material WAAM allows for 'completely new designs' combining mechanical performance with time and cost savings. The team also developed curved internal channels that follow the mold's contour, enabling more efficient heating and cooling.

The finished print was close to its target shape after 32 simulation iterations, which helped counter warping caused by residual stresses in the deposited metal. After printing, the mold was annealed to relieve internal stress and underwent further fabrication steps at Baker Industries in Michigan.