Baker Industries Inc. | Additive Manufacturing in Tooling

Additive Manufacturing

is Revolutionizing the Tooling Industry

Industry 4.0 is more demanding than ever before. Manufacturers across all sectors are being looked at to solve complex challenges facing ergonomics, performance, durability, and speed to market.

Additive manufacturing has revolutionized the industry and empowered these teams by removing design barriers to enable the creation of geometries that were previously not possible and/or affordable through traditional manufacturing. This has unlocked the door to faster innovation and exploration of improved designs, while still offering the same quality through high-performance materials.

The benefits of integrating AM into conventional manufacturing is clear, but in order to realize the full potential of AM, it’s imperative to have an expert guide to help you on your journey of uncovering the right applications, materials and processes.

Baker Industries will guide you on your journey into Additive

The Baker Industries team will support you in every step of the way; from identifying and evaluating AM candidates to exploring design improvements and supporting production. Our goal is to help you bring unparalleled tooling and components to the industry while transforming your business.

Why Baker Industries?

Baker Industries has been a leader in the tooling industry for over 25 years. Our first priority will always be to creatively solve our customers’ most complex challenges and provide them with complete tooling solutions. Making a case for AM integration has now become an integral part of our process, as we continually advocate for optimal tooling and functionality. This commitment to our customers’ success has earned the trust of some of the biggest names in OEM and Tier 1 manufacturing.

Experience the Benefits of AM Integration

Additive manufacturing offers unbelievable flexibility and functionality in terms of geometry. AM removes design barriers to enable the creation of shapes that were previously not possible and/or affordable through traditional manufacturing. This creates more space for innovation and exploration of improved designs.

AM offers endless opportunities for engineers to incorporate internal channels, curved features, cooling and heating efficiencies, varied layer thicknesses and honeycombed designs.

Additive Manufacturing enables weight reduction through a variety of design opportunities. 3D printing tools in one piece can potentially eliminate the need for fasteners and extra stock needed for assembly.

3D printing internal honeycomb structures can reduce overall weight, and can mitigate risks of injury while moving and handling components. Printing thermoplastics in place of heavy metal components can also improve plant ergonomics by reducing the need for cranes and other shop resources.

Our machines work with high-performance production grade thermoplastics and metals. All 3D printed metals are 99.9% as dense as traditional billet material, making any traditional post-processing possible.

Our metal (DMLS) machines hold tolerances up to +/- one to three thousandths of an inch, and our thermoplastic (FDM) machines hold tolerances up to +/- one to five thousandths of an inch. Both have the option to add material or post processing to achieve even tighter tolerances.

AM cuts down on the amount of material scrap that occurs during fabrication, improving product yield by saving money on material costs.

Labor inputs are often fewer in comparison to conventional tooling methods, as it may eliminate or reduce the need for machining and other processing steps. Manual assembly can often be avoided by printing complex components in a single piece.

3D printing is especially cost-effective for low-volume tooling. By 3D printing a physical part, you can quickly identify any design problems in the early stages of development. It can curtail some of the expensive costs caused by design changes.

AM also eliminates the need for managing inventories of old tools and components.

The cost advantages of AM allow for more frequent replacement tooling, which enables tooling design cycles to keep pace with product design cycles—inevitably leading to improved components and industry innovation.

Additive Manufacturing often requires fewer labor inputs and machining steps, which saves on time and processes. AM also requires the use of digital design files which may allow for simpler translation into production- with minimal time required for interpretation.

Overall, AM leads to creating tools in a fraction of the time it takes to traditionally manufacture them.  A typical aluminum or composite production tool requires approximately 2 months to design, produce, finish and ship, contrasted with 7 days required for an AM tool of similar size.

Common Applications

  • Jigs, Fixtures, & Gauges
  • Cutting / Trim Tools
  • Assembly Tools
  • Injection Molding Tools / Parts
  • Layup Tools
  • Washout Mandrels
  • Trapped Tooling
  • Autoclave Tooling
  • Metal Forming Dies
  • Conformal Cooling

Materials

Thermoplastics

  • ABS
  • ASA
  • Nylon
  • Polycarbonate
  • PPSF
  • ULTEM

Metals

  • Aluminum
  • Cobalt-Chrome
  • Maraging Steel
  • Stainless Steel
  • Nickel Alloy
  • Titanium

Secondary Services

Machining, fabrication and assembly are at the core of our business. With 35 CNC machines, 31 welders, 10 CMMs, and 9 laser trackers; we are more than equipped to handle all of your post-processing needs.

  • Support Removal
  • Polishing / Sanding
  • Machining
  • Heat Treatment
  • Trimming / Grinding
  • Welding
  • Filling / Gluing / Painting / Sealing
  • Gap Filling
  • Dipping
  • Epoxy Coating
  • Metal Coating
  • Bonding of Multiple Sections
certification

Ready to Integrate?

Combining 25 years of tooling industry intelligence with the latest technologies and applications in additive manufacturing, our team has what it takes to guide you through you journey into AM integration.