Printed vs. Traditional: A Head-to-Head Tooling Comparison
Thermwood, Aria Composite Technologies and Purdue University put a two-sided autoclave drone layup tool to the test.
The Project
For most manufacturers, the question isn't which 3D printer to buy. It's whether printed composite tooling can match or beat the way they build tools today.
To answer that directly, Thermwood, Aria Composite Technologies and Purdue University built the same two-sided autoclave layup tool for a blended wing drone body two ways: by the traditional method, and printed on an LSAM in 20% carbon fiber reinforced polycarbonate.
The results were definitive. The LSAM tool outperformed the traditional method in cost, speed and overall performance.
From Design to Finished Part
The Specs
- Tool dimensions: 49.725" x 21.8" x 5.322" (1263 mm x 554 mm x 135 mm)
- Material: Polycarbonate with 20% carbon fiber reinforcement
- Print time: 7 hours 23 minutes (2 complete sets)
- Material usage: 252 lb / 114 kg (1 complete set)
- Machining time: 17 hours (1 complete set)
The Results
- 34.8% total cost reduction
- 39.2% labor cost reduction
- 24.4% material cost reduction
- 75% faster tool creation
The Cost Breakdown
Industry Feedback
“Tools were easier to work with, excellent performance with no signs of wear after 6 complete cycles on each half. Signs are indicating improved cosmetic part finish directly off tool!”
Kevin Cain, Chief Technology Officer, Aria Group
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