With respect to the rising variety of model versions compared with a higher product complexity, the development of low cost and rapid sheet metal forming tools for the automotive industry for short production runs is a very interesting application. The surface quality and wear resistance of sheet metal forming tools for short production runs as well as for high volume production is unmistakable higher compared to “low quality” tools for prototyping. On the other hand rapid tooling techniques like laser sintering are limited with respect to size, edge life and surface quality. The development shown here outlines the potential of thermal spraying in the field of rapid production tooling. The tooling described here overcomes the limitations of rapid tooling techniques by using conventional rapid-prototyping and thermal spraying technologies. Paper text in German.

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