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Innovative Rapid Tooling in Additive Manufacturing Processes
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Innovative Rapid Tooling in Additive Manufacturing Processes

A special issue of Journal of Manufacturing and Materials Processing (ISSN 2504-4494).

Deadline for manuscript submissions: 31 May 2025 | Viewed by 2143

Special Issue Editors

Dr. Luca Giorleo

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Guest Editor
Department of Mechanical and Industrial Engineering, University of Brescia, Brescia, Italy
Interests: additive manufacturing; metal forming process; laser material processing; polymer testing
Dr. Gianluca Trotta

E-Mail Website
Guest Editor
STIIMA-CNR, Institute of Intelligent Industrial Systems and Technologies for Advanced Manufacturing, National Research Council of Italy, 70124 Bari, Italy
Interests: micro manufacturing; micro-devices; micro-injection molding; laser microfabrication; smart manufacturing; digital twins; process monitoring; the design of experiments; process optimization; quality process control
Special Issues, Collections and Topics in MDPI journals
Dr. Alessia Teresa Silvestri

E-Mail Website
Guest Editor
Department of Chemical, Materials and Industrial Production Engineering, University of Naples Federico II, Naples, Italy
Interests: additive manufacturing; friction stir welding; characterization; metallurgy; mechanical properties; surface analysis

Special Issue Information

Dear Colleagues,

In today’s market, a significant portion is driven by the demand for highly customized products with reduced production times. As a result of this customization, there has been a shift towards medium or low batch production, rendering traditional processes like casting and forming economically unsustainable due to the initial investment required for tool production.

Conversely, producing goods directly using additive manufacturing processes can also be costly if the production volume is in the hundreds, and this method undoubtedly leads to an increased production time due to the layering approach characteristic of these processes.

Rapid tooling represents a hybrid approach, combining the production of tools for traditional processes with additive manufacturing. This strategy could be the optimal solution to achieve faster production times while keeping conventional processes economically viable, even as production rates decrease.

This Special Issue explores ongoing research in additive manufacturing technologies, tool materials, tool design, and industrial applications, focusing on the potential of rapid tooling to transform the metalworking industry.

Dr. Luca Giorleo
Dr. Gianluca Trotta
Dr. Alessia Teresa Silvestri
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Journal of Manufacturing and Materials Processing is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 1800 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • additive manufacturing
  • 3D printing
  • design for additive manufacturing
  • topology optimization
  • conformal cooling
  • lattice structure
  • material extrusion
  • power bed fusion
  • rapid casting
  • rapid forming

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Published Papers (2 papers)

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Research

27 pages, 16445 KiB  
Article
Procedure for Reconstruction, Modeling, and Fabrication Using Additive and Rapid Tooling Methods of a Training Model for Transsphenoidal Surgery
by Giacomo Santona, Antonio Fiorentino, Francesco Doglietto and Mauro Serpelloni
J. Manuf. Mater. Process. 2025, 9(2), 63; https://doi.org/10.3390/jmmp9020063 - 18 Feb 2025
Viewed by 414
Abstract
The endoscopic transsphenoidal approach (ETA) is a novel approach used by neurosurgeons and otolaryngologists to treat pituitary adenoma, and it has a long learning curve. Training is mostly performed using cadaver heads, but their low availability and cost can limit their use. ETA [...] Read more.
The endoscopic transsphenoidal approach (ETA) is a novel approach used by neurosurgeons and otolaryngologists to treat pituitary adenoma, and it has a long learning curve. Training is mostly performed using cadaver heads, but their low availability and cost can limit their use. ETA training models can be used to overcome these limitations. In this panorama, additive manufacturing (AM) technologies represent a more flexible and cost-effective solution to fabricate custom-made training models. Their development involves computed tomography (CT) segmentation, STL file elaboration, direct 3D printing, and rapid parts tooling. This work presents and discusses the entire procedure applied to a modular ETA training model. The procedure starts with selecting the material and AM processes based on a literature review. Accordingly, the parts of the model were designed, 3D printed, or rapid cast. In particular, fused filament fabrication (FFF) was adopted for those tissues whose materials could be directly printed (bones and cartilage), while the rapid casting of silicone was adopted for soft tissues (skin and mucosa) together with FFF to fabricate mold patterns and cores. After fabrication and assembly, the model was finally tested by an experienced neurosurgeon who provided feedback. Moreover, the cost and time of the prototype fabrication were assessed. Results validated the proposed solution from both the surgical and commercial points of view. Moreover, general procedures for designing and rapidly fabricating ETA models were generalized to make them exploitable to more general case studies. Full article
(This article belongs to the Special Issue Innovative Rapid Tooling in Additive Manufacturing Processes)
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11 pages, 12682 KiB  
Article
Polymer Tools Produced by Fused Filament Fabrication for Steel-Bending Process: Effect of Layering Orientation
by Luca Giorleo and Kudret Irem Deniz
J. Manuf. Mater. Process. 2024, 8(6), 243; https://doi.org/10.3390/jmmp8060243 - 31 Oct 2024
Cited by 1 | Viewed by 1075
Abstract
Rapid tooling with polymer tools produced via additive manufacturing offers significant benefits in sheet metal forming processes as it allows for the production of parts with high accuracy while reducing tool production costs. In this research, the authors evaluate the performance of polymer [...] Read more.
Rapid tooling with polymer tools produced via additive manufacturing offers significant benefits in sheet metal forming processes as it allows for the production of parts with high accuracy while reducing tool production costs. In this research, the authors evaluate the performance of polymer punches and dies in the sheet metal bending of 2 mm thick AISI 314 stainless steel. The tools were made using nylon filled with carbon fiber and produced through Fused Filament Fabrication. Two different print orientations—horizontal and vertical—were compared. This experimental study focused on the accuracy of the sheet’s bending angle and thickness while also measuring the deformation induced in the tools. A new methodology was proposed combining both tools and sheet measures to highlight not only the sheet’s accuracy but also the behavior of the polymer tools. The results demonstrate that despite the permanent deformation of the tools, they were able to produce sheets with a geometry accuracy of less than 0.5% Full article
(This article belongs to the Special Issue Innovative Rapid Tooling in Additive Manufacturing Processes)
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