Reducing the Cost of 3D Metal Printing Using Selective Laser Melting (SLM) Technology in the Manufacture of a Drill Body by Reinforcing Thin-Walled Shell Forms with Metal-Polymers

This article describes the technology for manufacturing a metal composite structure of a metal-cutting tool body. The main problem with using metal 3D-printing is its prohibitively high cost. The initial data for carrying out finite element calculations are presented, in particular, the calculation and justification of the selected loads on the drill body arising from metal-cutting forces. The described methodology for designing a digital model of a metal-cutting tool for the purpose of its further production using SLM 3D metal printing methods facilitates the procurement of a digital model characterized by a reduced weight and volume of material. The described design technology involves the production of a thin-walled outer shell that forms the external technological surfaces necessary for the drill body, as well as internal structural elements formed as a result of topological optimization of the product shape. Much attention in this article is paid to the description of the technology for filling internal cavities with a viscous metal polymer, formed as a result of the topological optimization of the original model. Due to this design approach, it is possible to reduce the volume of 3D metal printing by 32%, which amounts to more than USD 135 in value terms.