CEAD large format additive manufacturing solutions revolutionise various markets and industries. One of the critical applications of CEAD’s technology is found in the production of (autoclave) molds and tooling.

This pages dives into the advantages of large format additive manufacturing for autoclave molds and tooling, the unique characteristics of CEAD’s Flexbot and more. For more information and advice for your application of industrial 3D printing, contact CEAD’s specialists directly.

The use of autoclave moulding is prevalent in high-performance industries where superior material properties, lightweight end parts and high-precision are of great importance. The following industries and markets use 3D printed autoclave molds and tooling:

The high-pressure and high-temperature environment of an autoclave are used for end-parts that have specific requirements. The following are advantages of using autoclaves for molds and tooling:

• Superior material properties: the autoclave’s environment ensures that composite materials and resins achieve optimal bonding and curing. This results in stronger, lighter, and more durable end-parts.
• Precision and consistency: autoclave moulding allows for the highly precise creation of molds and tooling. These precision ensures consistent end-parts.
• Complex shapes: autoclaves can accommodate moulds in complex shapes that industrial 3D printing is able to produce. This allows for design freedom and the creation of parts with precise dimensions and flawless finishes.

One of the characteristics of CEAD’s pellet extruders and industrial 3D printing solutions, is that they are able to process a wide variety of 3D printing materials. There are various materials that are suitable for autoclave use. The ideal 3D printing material for autoclaves depends on various aspects, such as the autoclave cycle, maximum temperature and available budget.

When producing autoclave moulds, one of the main requirements is that the 3D printing material used must provide aerospace-grade tolerances. This ensures that the final components meet the stringent performance, reliability, and safety standards required in high-stakes applications like aviation.

Besides these tolerances, the following considerations should be taken into account when selecting the right material for large format additive manufacturing of autoclave molds and tooling:

• Fiber reinforced: by reinforcing 3D printed material with fibers, the material obtains a lower CTE and increased mechanical properties. Carbon fibers are less cost-effective than glass fibers, but provide more rigidness and are lighter. Carbon fiber reinforced material is therefore used to obtain higher tolerances and to positively influence the CTE.
• Maximum temperature: because autoclaves use elevated temperatures to produce molds, the 3D printed material should withstand these temperatures. Frequently maximum temperatures are 140°C of 180°C. Optimal materials for these applications can be carbon-fiber reinforced Polycarbonate or PEI.
• Cost-effectiveness: due to the high requirements associated with 3D printing material suitable for autoclave use, it generally brings along more costs than standard 3D printing material. PET-G for example typically ranges around €5,50 per kilo, ABS materials range from €30,- to 60,- per kilo.

CEAD developed a complete solution for the hybrid manufacturing of molds and tooling for autoclaves: the Flexbot. This machine combines the benefits of additive manufacturing (3D printing) and subtractive manufacturing (milling) in a single, versatile platform.

The Flexbot can be used to produce near-net-shapes of molds and for post-processing of printed molds to obtain the desired surface finish and textures. This hybrid approach ensures that even the tightest tolerances are met.

CEAD’s application engineers have extensive experience in material testing, design for additive manufacturing and process optimization. The expertise of this team ensures that the your Flexbot system is able to deliver the highest quality results for your specific application.

Contact sales@ceadgroup.com for more information concerning your application of large format 3D printing or download the Flexbot brochure directly.