TRANSFORMING MOLD MANUFACTURING: A REVIEW OF ADDITIVE MANUFACTURING IN METALLIC AND COMPOSITE TOOLING

Abstract

Additive manufacturing (AM) is reshaping traditional mold production by enabling the fabrication of complex, customized structures with improved material efficiency and reduced lead times. This paper investigates the application of AM in the production of metallic and composite molds, focusing on key techniques such as Powder Bed Fusion (PBF), Directed Energy Deposition (DED), Binder Jetting, and Vat Photopolymerization. The study evaluates material suitability, design flexibility, sustainability, and process efficiency, while also addressing existing challenges such as high production costs, material limitations, and post-processing demands. Furthermore, it highlights recent advancements in multi-material printing, process automation, and hybrid manufacturing approaches. By synthesizing recent research and technological trends, this work offers insights into the evolving role of AM in mold manufacturing and its potential to replace or complement conventional mold fabrication methods across diverse industries.