“Additive manufacturing will become standard practice in tooling within five years. New materials will match traditional tool steels. Multi-material machines will combine different materials in one tool. Hybrid machines merging additive and traditional machining will become common. Automation and AI will make the technology easier to use for traditional tool rooms”, says Ankit Sahu, CEO and Founder at Objectify Technologies Pvt. Ltd., in conversation with Neha Basudkar Ghate.
What are the key advantages of additive manufacturing in the design and production of complex tooling, dies, and moulds compared to conventional methods?
Additive manufacturing builds tools layer by layer, creating shapes impossible with traditional cutting. The main benefit is making one complete tool instead of joining 15-20 separate pieces. This eliminates assembly work and weak points. We use only the material we need, unlike traditional methods that waste 60-70% by cutting away excess. We can also build in cooling channels and air vents during the process itself, so tools work better immediately without additional work.
How can the integration of conformal cooling channels via additive manufacturing shorten cycle times and improve tool life in injection moulding and die casting?
Traditional cooling uses straight drilled holes that create hot and cold spots. With additive manufacturing, we make cooling channels that follow the mould’s exact shape, providing even temperature control. This reduces cycle times by 25-40%, meaning faster production and more parts daily. Even cooling also extends tool life by 30-50% by reducing stress. The investment pays back within 6-12 months through higher productivity and fewer tool replacements.
How does additive manufacturing enable the production of single-piece, tolerance-critical tooling components that were difficult to achieve with traditional machining?
We can now produce complex tooling as one complete piece instead of assembling multiple parts. This eliminates alignment problems and gaps affecting accuracy. Tool inserts with cooling channels, ejector holes, and mounting features are built together in one go. We combine additive manufacturing for complex shapes with traditional machining for precision surfaces, achieving tight tolerances. The real breakthrough is creating internal geometries impossible to reach with conventional tools, opening new design possibilities.
In what ways does additive manufacturing support rapid prototyping and iterative development of custom tooling and machine parts for diverse industries?
Additive manufacturing cuts development time from months to weeks. We go from design to physical part in days, not months. Engineers can test, improve, and remake tools within a week. This speed is revolutionary for custom fixtures and production aids. Companies use prototype tooling to validate designs before investing in expensive final tools. Some automotive suppliers produce 500-5,000 parts with additive manufactured bridge tooling during product launches, perfect for specialized low-volume components.
How do global trends in additive manufacturing influence the development and adoption of advanced tooling and machine design technologies in India?
Globally, companies are using additive manufacturing for actual production, not just prototypes. Aerospace and automotive manufacturers produce millions of parts annually, proving the technology works. This gives Indian manufacturers confidence to invest. Government initiatives like Make in India support adoption. Global companies in India bring knowledge and capabilities. However, China has invested heavily in this technology. India must accelerate adoption and worker training to stay competitive in global tooling markets.
What are the technical challenges in scaling additive manufacturing for large, high-precision tooling used in automotive and aerospace sectors?
Most metal additive manufacturing machines have limited build sizes under 500mm, while automotive and aerospace tools are larger. We must print parts in sections and join them, requiring careful planning. Maintaining consistent quality across large builds is challenging. Aerospace parts need strict certifications demanding rigorous quality control. Managing large quantities of metal powder adds complexity. High equipment and operational costs create barriers. The business case must clearly show advantages over conventional methods.
How can emerging technologies such as AI and machine learning be integrated into additive manufacturing R&D to improve design accuracy and predictive maintenance of tooling components?
AI automatically designs structures optimized for manufacturing and performance in hours instead of weeks. Machine learning identifies best printing settings for different designs, eliminating trial-and-error testing. AI-powered sensors detect problems during printing in real-time, preventing failures and saving materials. For tool maintenance, AI predicts when servicing is needed before unexpected failures disrupt production. These technologies require investment but deliver major benefits in quality consistency and faster development.
How do you envision additive manufacturing evolving to further transform manufacturing tooling and machine design landscapes in the next five years?
Additive manufacturing will become standard practice in tooling within five years. New materials will match traditional tool steels. Multi-material machines will combine different materials in one tool. Hybrid machines merging additive and traditional machining will become common. Automation and AI will make the technology easier to use for traditional tool rooms. Most importantly, engineers trained in additive design are entering the workforce and will completely rethink what tooling can be.
What are the key lessons learned from global additive manufacturing research initiatives that can be applied to strengthen India’s domestic tooling and die manufacturing capabilities?
Success requires collaboration between equipment makers, material suppliers, educational institutions, and manufacturers. Germany’s research institutes working with industry provide a good model. India needs similar organizations helping small companies access technology without huge investments. Skills training is critical—we should use existing technical training networks for additive manufacturing programs. Shared research facilities accelerate industry development. India should focus on our strengths—automotive tooling and precision dies—to strengthen global competitiveness.
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