Навчально-науковий центр "Мости та тунелі" (раніше Факультет "Мости і тунелі") ДІІТ
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ENG: Educational and Scientific Center (Faculty "Bridges and Tunnels") DIIT
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Browsing Навчально-науковий центр "Мости та тунелі" (раніше Факультет "Мости і тунелі") ДІІТ by Subject "3D printing"
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Item Investigation of Digital Light Processing-Based 3D Printing for Optimized Tooling in Automotive and Electronics Sheet Metal Forming(MDPI, Basel, Switzerland, 2025) Szalai, Szabolcs; Szívós, Brigitta Fruzsina; Nemes, Vivien; Szabó, György; Kurhan, Dmytro; Sysyn, Mykola; Fischer, SzabolcsENG: This study addresses the emerging need for efficient and cost-effective solutions in low-volume production by exploring the mechanical performance and industrial feasibility of cutting tools that are fabricated using stereolithography apparatus (SLA) technology. SLA’s high-resolution capabilities make it suitable for creating precise cutting dies, which were tested on aluminum sheets (Al99.5, 0.3 mm, and AlMg3, 1.0 mm) under a 60-ton hydraulic press. Measurements using digital image correlation (DIC) revealed minimal wear and deformation, with tolerances consistently within IT 0.1 mm. The results demonstrated that SLA-printed tools perform comparably to conventional metal tools in cutting and bending operations, achieving similar surface quality and edge precision while significantly reducing the production time and cost. Despite some limitations in wear resistance, the findings highlight SLA technology’s potential for rapid prototyping and short-run manufacturing in the automotive and electronics sectors. This research fills a critical gap in understanding SLA-based tooling applications, offering insights into process optimization to enhance tool durability and broaden material compatibility. These advancements position SLA technology as a transformative tool-making technology for flexible manufacturing.Item Investigation of FDM-Based 3D Printing for Optimized Tooling in Automotive and Electronics Sheet Metal Cutting(MDPI, Basel, Switzerland, 2025) Szalai, Szabolcs; Szívós, Brigitta Fruzsina; Nemes, Vivien; Szabó, György; Kurhan, Dmytro; Sysyn, Mykola; Fischer, SzabolcsENG: Within the scope of the work, the possible use of fused deposition modeling (FDM) technology in executing rapid prototypes of cutting tools for aluminum sheets was systematically studied. Relevant investigations have thus far mainly concentrated on tools for the 3D printing of bent and deep-drawn pieces, yet the implementation of FDM tools in cutting has been insufficiently covered. This study aims to determine the characteristics of FDM cutting tools, such as wear and tear, dimensional stability, and cutting efficiency. Various tool designs were tested under different wall thicknesses and orientations with respect to the feed of Al99.5 sheets with thicknesses of 0.22 mm and 0.3 mm. According to the results, in the best case, three-dimensional printed PLA tools performed six cuts with no burrs and an acceptable wear level due to the IT tolerances (IT9 and IT10). Tools with thicker walls and more appropriate orientations were found to be more robust. However, some designs failed when subjected to greater loads, revealing a deficiency in some of the strength properties of the material. These observations suggest that it is possible to create 3D printed tools for modeling and small-scale production at considerably cheaper and faster rates than conventional methods. Future work will integrate advanced materials and designs to enhance tool performance, further solidifying FDM as a transformative approach in industrial tool manufacturing. With this research, the authors wanted to demonstrate that FDM technology can also be used to produce a classic sheet cut, which, of course, is still of great importance for prototyping or setting up production processes. This research demonstrated that FDM printing can play a role in this area.Item Optimization of 3D Printed Rapid Prototype Deep Drawing Tools for Automotive and Railway Sheet Material Testing(MDPI, 2023) Szalai, Szabolcs; Herold, Bálint; Kurhan, Dmytro; Németh, Attila; Sysyn, Mykola; Fischer, SzabolcsENG: The main objective of this research is to identify optimal printing strategies and PLA (polylactic acid) filament materials to produce rapid prototype deep drawing tools. Additive 3D printing technologies have been applied for a long time to produce tools, but the research is unique in that it uses conventional and various reinforced PLA materials with conventional FDM (Fused Deposition Modeling) printers. The advantage of this method is that PLA is easy to print and recycle and does not require expensive or special printers, this also gives the article its novelty. A further aim was to produce the tools using commercially available low-end printers. DX53D 0.8 mm thick body steel and AlMg3 2.5 mm thick sheet were the materials to be molded for the tests. The test tool was an Erichsen deep drawing punch. Tool wear was tested using the GOM ATOS measuring system, an optical coordinate measuring machine based on the DIC (Digital Image Correlation) principle, which is also popular in the automotive industry. The study aims to determine the 3D printing and material parameters that can safely produce a minimum batch of 100 parts.