Topology Optimization of Polymer-Based Bending Tools Manufactured via Additive Technology: Numerical and Experimental Validation

• Published in: Journal of Manufacturing and Materials Processing Vol. 9; no. 9; p. 310
• Main Authors: Giorleo, Luca, Deniz, Kudret Irem
• Format: Journal Article
• Language: English
• Published: Basel MDPI AG 01.09.2025
• Subjects: 3D printing; Accuracy; additive manufacturing; Batch production; Bending; Carbon; Cost control; Cost effectiveness; Design; Elastic deformation; Energy consumption; Feasibility studies; Finite element method; Friction; Fused deposition modeling; Geometry; Heat resistance; International economic relations; Manufacturing; Mathematical analysis; Metal forming; metal replacement; Metal sheets; Metalworking machinery; Optimization techniques; polymer; Polymer industry; Polymers; Prototyping; rapid tooling; Safety factors; sheet bending; Sheet-metal; Simulation; Software; Stress concentration; Structural integrity; Tooling; Topology optimization
• ISSN: 2504-4494; 2504-4494
• DOI: 10.3390/jmmp9090310

Sheet metal forming is a widely used manufacturing process, but the high cost and long production time of traditional forming tools limit its flexibility, especially for prototyping and small-batch production. Additive manufacturing offers a promising alternative, enabling the rapid and cost-effective fabrication of customized tools. In this study, bending tools were produced using Fused Filament Fabrication and optimized through a topology optimization approach. A combined experimental and numerical approach was applied to validate standard tool geometries and extract load conditions for use in a topology optimization process. The resulting optimized punch and die achieved a mass reduction of approximately 50% while maintaining structural integrity and safety factors well above critical thresholds. Finite Element Analysis revealed an increase in elastic deformation and stress concentration in non-critical regions, without compromising tool functionality. Experimental tests with the optimized tools confirmed their suitability for sheet metal bending, although a decrease of about 2° in the bending angle and an increase in variability were observed, consistent with simulation results. The study demonstrates the feasibility of using topology-optimized polymer tools for low-volume forming applications, offering a lightweight, cost-effective, and sustainable alternative to traditional metal tooling.