BLT demonstrates advantages of Additive Manufacturing for advanced cutting tools
Xi’an Bright Laser Technologies Co., Ltd (BLT), China, has published a study discussing the use of Additive Manufacturing for the production of cutting tools. Driven by the growing demand in high-end manufacturing sectors, the market demand for large cutting tools is expanding rapidly, the company stated. This has led to the continuous introduction and development of new technologies and materials in tool manufacturing to enhance the performance and service life of cutting tools.
As a core component in mechanical manufacturing, cutting tools are widely used in various fields like machining, automotive, aerospace, electronics and medical device industries. Their performance and quality directly determine machining efficiency and product quality, explains BLT.
In recent years, machining processes have maintained their key role in global manufacturing, with a growth in steady market demand. The shift towards intelligent manufacturing has led the tooling industry to undergo a transformation from traditional manual or machine-based interchangeable tools to more advanced technological solutions.
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Highly customised cutting tools and solutions are often challenging to achieve through traditional subtractive manufacturing processes. Leveraging its capabilities in lightweight design, high quality, precision manufacturing, and integrated forming, Additive Manufacturing enables the production of cutting tools that better meet the demands of advanced manufacturing. Furthermore, these AM tools can deliver superior performance and extended service life compared to conventional counterparts, BLT added.
Integrated manufacturing – reducing operational energy and resource waste
BLT has redesigned milling cutter discs and tool holders through metal Additive Manufacturing using its BLT-S400. Compared to traditional manufacturing processes, this method not only reduces material waste caused by cutting operations, but also allows for the complete recycling of unused metal powders, significantly reducing resource consumption.
BLT has engineered more sophisticated flute geometries that not only minimise reliance on traditional machine and processes, but also achieve remarkable weight reduction. The final products weigh just 0.524kg for the milling cutter disc and 0.228kg for the tool holder. This innovative design achieves reductions in both operational energy consumptions and resource waste.
Optimised cooling channel design – extending tool service life
The cutting tools manufactured via BLT-S400 not only feature optimised structural designs but also demonstrate extended service life. Unlike conventional machining methods that rely on drilled cooling channels, which are limited to simple geometries, AM enables optimised coolant channels designed from the outset. These channels directly and efficiently deliver coolant to the cutting edge, preventing overheating and hardness reduction. This enhancement improves cooling and lubrication effectiveness, thereby extending tool service life.
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