Kennametal

INDUSTRY TRENDS

3D Printing the Future of E-Mobility Tools

Kennametal develops 3D printed lightweight stator bore tool, that meets accuracy, roundness,
and surface nish requirements.
Kennametal | Oct 29, 2019

Kennametal has developed a 3D printed stator bore tool specifically designed to meet growing
customer demand for lighter weight tooling solutions used to machine components for hybrid and
electric vehicles.

E-mobility components are typically machined on smaller, low horsepower CNC machining centers
that require lighter weight tooling solutions. Kennametal’s 3D printed stator bore tool weighs half that
of the conventionally manufactured version, while still meeting accuracy, roundness, and surface finish
requirements for aluminum motor body boring.

“The main bore, that houses the stator of an electric motor, measures approximately 250 mm in
diameter (9.84") and approximately 400 mm (15.74") in length, with a smaller bearing bore at the
bottom,” said Harald Bruetting, Manager, Program Engineering. “When manufactured using
conventional means, a reamer for this type of application would weigh more than 25 kilograms (55 lb.),
far too heavy for the existing machine tool or for an operator working with the tool.”

Bruetting and Kennametal’s Solution Engineering Group turned to the company’s in-house additive
manufacturing capabilities to 3D-print a strong but lightweight indexable tool, equipped with proven
Kennametal technologies including fine adjustable RIQ reaming inserts for high precision finishing and
a KM4X adaptor for maximum rigidity. The tool also features internal 3D printed cooling channels that
help maximize productivity and tool life.

“By using metal powder bed 3D-printing together with finite element analysis software, we were able to
design and build a tool that brought the moment of inertia very close to the spindle face, increasing its
rigidity while meeting the customer’s weight restrictions,” said Werner Penkert, Manager, Future
Solutions. “It is an excellent example of how Kennametal is using advanced manufacturing technology
to help meet our customer’s unique challenges.”

Two versions of the tool were built, one with a carbon-fiber tube, the other using a 3D-printed metal
tube. The results were impressive. The tool with the 3D printed tube weighed in at 10.7 kg (23.6 lb.)
and the carbon fiber version at 9.5 kg (20.9 lb.), less than half of their conventional
counterparts.

Leveraging proven Kennametal technologies. High precision RIQ reaming inserts, and KM4X adaptor
for the highest possible rigidity.
Weight reduction through additive layer manufacturing. 3D-printed, total weight of 10.7 kg. Cutting the
weight in half, meeting surface quality, roundness, and accuracy requirements for stator bores.

Same tool, even lighter. Instead of using a 3D printed metal tube, a tool version with a carbon fiber tube
was used. Reducing the weight even further, down to 9.5 kg.

Source URL: https://www.newequipment.com/industry-trends/3d-printing-future-e-mobility-tools