Kennametal used 3D printing to cut the weight of a stator bore tool from 9.5 kg (left) to 7.3 kg (right).

The latest iteration of a 3D-printed stator bore tool from Kennametal weighs just 7.3 kg, which, the toolmaker says, ensures short tool-change and spin-up time when run on a machining center.

Intended for machining the aluminum engine housings of electric vehicles, the tool features a newly designed arm structure and a larger center tube made of carbon fiber. The complex tool is capable of machining three large diameters in one pass, saving setup and machining time for automotive component manufacturers while delivering high accuracy and a fine surface finish, claims the company.

“As our automotive customers expand their offerings of hybrid and electric vehicles, we continue to respond to their need for lighter-weight tooling solutions,” said Kennametal’s product manager, Ingo Grillenberger. “By leveraging advanced manufacturing techniques like 3D printing, we’ve reduced weight a further 20% over the first-generation tool.”

The Additive Report focuses on the use of additive manufacturing technology in the real world of manufacturing. Today’s manufacturers are using 3D printing technology to create tools and fixtures, and some are even using AM for high-volume production work. Their stories will be covered here.

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