Topology Optimization of Polymer-Based Bending Tools Manufactured via Additive Technology: Numerical and Experimental Validation

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The optimized punch and die achieved a mass reduction of approximately 50%, maintaining safety factors above critical thresholds.
Finite Element Analysis indicated an increase in elastic deformation and stress concentration in non-critical regions.
Experimental tests revealed a decrease of about 2° in the bending angle with the optimized tools, consistent with simulation results.
The use of topology-optimized polymer tools offers a lightweight and sustainable alternative to traditional metal tooling for low-volume production.

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Experimental validation showed that optimized bending tools reduce weight by 50%, indicating improved efficiency in sheet metal forming.

Giorleo et al. (2025) studied this question.

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