Towards next-generation cutting tools: Laser powder bed fusion of topology-optimized WC-Co endmills

Abstract

Additive manufacturing offers a transformative approach to reducing material waste and energy consumption by enabling the fabrication of complex, high-performance structures with greater sustainability. This study harnesses that potential in the context of cutting tool production, presenting a topology-optimized WC-Co endmill. The design was realized using a 3D finite element model based on the Solid Isotropic Material with Penalization (SIMP) method. The tool was subsequently produced via Laser Powder Bed Fusion, finish-ground, and experimentally tested. Results show that the mass of the endmill can be reduced by up to 63% without compromising its function when milling 6061 Al. Moreover, this hybrid manufacturing approach cuts energy consumption during fabrication by 89% compared to conventional methods. Modal tap testing further revealed an 18% increase in the limiting depth of cut, indicating improved dynamic stability. These findings validate the effectiveness of hybrid manufacturing for topology-optimized WC-Co rotating tools, demonstrating significant gains in both sustainability and operational performance.