1. Introduction

The sheet metal forming industry is a critical component of modern manufacturing, supporting sectors ranging from automotive and aerospace to consumer electronics and construction. A key challenge in this field is the cost and lead time associated with creating custom form dies, which are essential for producing complex parts. Traditional die manufacturing methods, such as CNC machining, are often expensive and time-intensive, limiting design flexibility and making low-volume production economically unfeasible. This project addresses these limitations by developing an innovative, fully 3D-printed solution for creating durable, reliable, and accurate sheet metal form dies that are both customizable and cost-effective.

​

2. Project Goals

The primary objective of this project is to create an industry-leading line of customizable sheet metal form dies with the following key characteristics:

​​

• Durability: The dies will be manufactured using advanced, high-strength composite materials to withstand the significant forces involved in sheet metal forming, ensuring a long operational lifespan.

• Reliability: The production process will be standardized to guarantee consistent performance and repeatable results across all manufactured dies.

• Accuracy: The dies will be produced with high precision, achieving tight dimensional tolerances to meet the rigorous quality standards required for end-use parts.

• Customization: The design process will be fully digital, allowing for rapid and simple modification of die geometry to suit unique part specifications. This includes variations in part profiles, radii, and other critical features.

• 3D Printing: The entire die will be manufactured using advanced additive manufacturing (3D printing) technologies. This approach significantly reduces lead times, material waste, and manufacturing costs compared to traditional methods.

​

3. Project Scope

This project will encompass the following activities:

• Material Selection and Testing: Identify and validate high-performance polymer or composite materials suitable for 3D printing form dies. This includes extensive mechanical testing to evaluate properties such as compressive strength, wear resistance, and fatigue life.

• Design and Optimization: Develop a modular and parametric design framework for the form dies. This framework will allow for quick customization based on customer-provided 3D models or specifications. The designs will be optimized for additive manufacturing, including considerations for stress distribution and support structures.

• Manufacturing Process Development: Establish a robust workflow for 3D printing the dies, including material preparation, printer calibration, and post-processing techniques (e.g., curing, surface finishing) to enhance mechanical properties and dimensional accuracy.

• Prototyping and Validation: Produce a series of prototype dies and rigorously test them on a standard sheet metal press brake or forming machine. The validation process will involve forming various sheet metal materials (e.g., aluminum, steel) and measuring the resulting parts against design specifications for accuracy and quality.

• Market Viability and Commercialization: Develop a business case and go-to-market strategy for the customizable dies. This includes defining the target audience (e.g., prototyping shops, low-volume manufacturers), pricing models, and establishing an online platform for customers to submit designs and order their custom dies.

​

4. Expected Outcomes

• A validated process for 3D printing durable, reliable, and accurate sheet metal form dies.

• A library of standardized, customizable die designs that can be rapidly adapted to various manufacturing needs.

• Significant reduction in the cost and lead time associated with creating custom sheet metal forming tools.

• A new product offering that democratizes access to advanced manufacturing capabilities, empowering businesses to innovate with greater speed and flexibility.

• A significant advancement in the application of additive manufacturing for industrial tooling, opening new possibilities for on-demand production and supply chain optimization.

This project is poised to disrupt the traditional die manufacturing industry by leveraging the full potential of 3D printing to deliver a superior, more flexible, and economically viable solution for sheet metal forming.

​​

Donations will fuel the next generation of manufacturing by supporting the research and development of Customizable Sheet Metal Form Dies. This groundbreaking project leverages cutting-edge 3D printing technology and advanced materials to create durable, reliable, and highly accurate form dies.

​

By replacing traditional, costly, and time-consuming manufacturing methods, this innovation will dramatically reduce lead times and production costs, making high-precision tooling accessible to more businesses. This advancement will not only democratize access to advanced manufacturing capabilities but also accelerate innovation across various industries, from aerospace to consumer goods.

​

Your contribution is a direct investment in the future of manufacturing, helping us bring this project to reality and advance mankind's ability to create with speed, precision, and sustainability.

​

Ryan Drown

CEO Chimera Ink LLC

​