Additive Manufacturing of Mold Inserts in Die Casting Tools for Clutch Housings

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Additive manufacturing increases service life of tool inserts more than three times while reducing costs by over 50%.
Laser powder bed fusion technique is used for manufacturing tool inserts from maraging steel 1.2709.
Damage analysis identifies failure causes and provides recommendations to improve mold insert performance.
Conformal cooling achieved with additively manufactured tools may enhance production where conventional methods fall short.

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Research demonstrates additive manufacturing enhances service life of tool inserts in die casting, indicating economic benefits.

Hagenah et al. (2025) studied this question.

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