This article describes two rapid tooling technologies, namely, direct rapid tooling and indirect rapid tooling, for forging-die applications. Commonly used direct rapid tooling technologies include selective laser sintering, three-dimensional printing, and laser-engineered net shape process. The indirect rapid tooling technologies include 3D Keltool process, hot isostatic pressing, rapid solidification process tooling, precision spray forming, and radially constricted consolidation process.

This article addresses dies and die materials used for hot forging in vertical presses, hammers, and horizontal forging machines (upsetters). It reviews the properties of die materials for hot forging, including good hardenability, resistance to wear, plastic deformation, thermal fatigue, and mechanical fatigue. The article describes heat treating practices commonly employed for chromium- and tungsten-base AISI hot-work tool steels. It discusses the fabrication of impression dies, and the advantages and disadvantages of cast dies. The article concludes with a discussion on the factors that affect die life and safety precautions to be considered during die construction.

Forging machines use a wide variety of hammers, presses, and dies to produce products with the desired shape, size, and geometry. This article discusses the major types of hammers (gravity-drop, power-drop, high speed, and open-die forging), and presses (mechanical, hydraulic, screw-type, and multiple-ram). It further discusses the technologies used in the design of dies, terminology, and materials selection for dies for the most common hot-forging processes, particularly those using vertical presses, hammers, and horizontal forging machines. A brief section is included on computer-aided design in the forging industry. Additionally, the article reviews specific characteristics, process limitations, advantages, and disadvantages of the most common forging processes, namely hot upset forging, roll forging, radial forging, rotary forging, isothermal and hot-die forging, precision forging, and cold forging.