Zinc-based alloy rapid tooling for sheet metal forming reinforced by SLM steel inlays

Among the existing rapid and economical sheet metal–forming technologies, stamping with a press using soft tools, especially low-melting-point alloy dies, is one of few methods that can meet precision requirements in industrial fields such as automobile manufacturing. However, usability method limited by low strength base. The current study proposes new structure zinc-based dies for metal forming, where weak features die blocks, protruding edges, are reinforced selective laser melting steel inlays imbedded during solid–liquid compound casting. A technical route fabricating tools was developed, W-shaped part formed an SUS304 thickness 0.32 mm Al6061 1 to validate concept. experiment simulation results proved clearer localized features, smaller radius, be on workpiece reinforcement inlays, while springback abrasion resistance tool higher. This improve forming quality durability traditional convenient affordable way.