Case Study

    Laminate Mold Production Using Additive Printing

    75% development time reduction and 40% cost savings

    Project Context

    The client was developing a geometrically complex aerodynamic cover for a 50-piece series. A precise laminate mold was needed quickly for testing and subsequent small-series production.

    Challenge

    Challenge

    Traditional CNC machining production had fundamental limitations. The mold became a critical development bottleneck.

    • 8-week lead timeDelaying testing and the entire development cycle.
    • High costsFive-axis milling, material waste.
    • Low flexibilityDesign change = new mold + additional 2 months.
    Laminate Mold Production Using Additive Printing
    Additive Rapid Tooling from PA-CF

    Solution

    Additive Rapid Tooling from PA-CF

    Instead of machining, we chose direct 3D printing of the mold from composite material with carbon fiber (Nylon-Carbon).

    Key technical reasons

    • Geometric freedomProduction of complex radii and shapes.
    • Temperature resistance up to 120 °CSuitable for lamination and curing.
    • CAM programming eliminationNo five-axis milling needed. The result was a one-piece mold without design compromises.

    Implementation Process

    Implementation Process

    From CAD model optimization to geometry validation.

    Step 1

    CAD Model Optimization

    Adding internal ribs to increase rigidity.

    Step 2

    Additive Manufacturing

    Production on industrial equipment with emphasis on dimensional accuracy.

    Step 3

    Surface Finish

    Hand sanding and polishing of functional surfaces. Achieving quality for visible carbon.

    Step 4

    3D Geometry Control

    Validation against CAD model.

    Results

    Results Comparison

    ParameterTraditional CNC3D Printing
    Mold delivery8 weeks14 days
    Costs100%–40%
    Change flexibilityLowHigh

    Key Benefits

    • 75% reduction in production cycle
    • 40% cost reduction
    • Ability to start lamination weeks earlier
    • Elimination of technological risk when changing design

    Conclusion

    Conclusion

    Prototype and small-series molds produced using 3D printing proved to be effective bridge tooling in this project. Mold production stopped being a critical development bottleneck and became a fast, predictable step.