A Novel Low-Cost Tooling via a Hybrid Manufacturing Technology

Abstract Additive manufacturing (AM) methods provide a solution for rapid, cost-effective tooling that addresses the increasing demand for product customization and low- to medium-volume production. Despite the advantages of AM, challenges remain in mechanical and thermal stability, surface quality, and production costs. This paper presents a novel hybrid modular tooling (HMT) system, offering a low-cost, agile solution that combines multi-material modular design with hybrid manufacturing. The HMT system features a reusable steel base tool compatible with diverse applications and customized 3D-printed polymer inserts laminated with sheet metal formed through the hybrid polymer injection forming (PIF) process. This approach enhances tool durability, thermal stability, and surface quality while remaining cost-effective. The feasibility of this method is demonstrated through a case study that includes the design, simulation, and fabrication of an injection molding tool used to produce a part with complex geometries, evaluating the effectiveness of this approach in tool production. The results highlight the effectiveness of HMT in improving mechanical strength and surface quality for injection molding applications. Additionally, this system enables the integration of advanced functionalities, such as conformal cooling channels, to enhance production efficiency and embedded sensors for developing smart tools. These capabilities make HMT a suitable solution for industries requiring adaptable and cost-efficient tooling to meet evolving production demands while ensuring high-quality products.