3D-Printed Metal Tooling Is Driving the Future of Auto Manufacturing
Over in Tennessee, something rather ground-breaking is taking shape—layer by molten layer. Engineers at the U.S. Department of Energy’s Oak Ridge National Laboratory (ORNL) have made a bold leap in manufacturing, using 3D-printed metal moulds to produce large composite components for automobiles. And if their research is anything to go by, this isn’t just another technological flex—it’s a major turning point for U.S. auto manufacturing.
With the global race to modernise production lines and reduce emissions heating up, this advancement couldn’t have landed at a better time. “This kind of technology can help reindustrialise the U.S. and boost its competitiveness by creating smarter, faster ways to build essential tools,” said Andrzej Nycz, lead researcher at ORNL’s Manufacturing Robotics and Controls group. “It brings us closer to an automated, intelligent production process.”
In other words, what we’re witnessing is the convergence of robotics, smart manufacturing, and sustainable thinking—all under one automated roof.
A Cleaner Way to Build
Traditional tooling methods are, quite frankly, a bit of a headache. Think massive blocks of forged steel, painstakingly carved away using subtractive machining. It’s a process that often results in a staggering 98% of the original material being discarded as waste. Worse still, supply chain delays can push delivery times to months on end. Not ideal if you’re trying to build a battery-electric SUV on a tight schedule.
Now flip that on its head.
Additive manufacturing—also known as 3D printing—builds components layer by layer using widely available welding wire. The waste? Slashed to about 10%. It’s more precise, more agile, and more adaptable to modern design needs.
And the real kicker? It opens the door to advanced geometries that conventional machines simply can’t handle. “The more complex the shape, the more valuable additive manufacturing becomes,” Nycz explained.
Turning Theory into Tangible Innovation
This isn’t just blue-sky thinking. ORNL teamed up with Collaborative Composites Solutions (CCS), operator of IACMI–The Composites Institute, to prove the concept in a real-world application. Their test subject: a full-size mould for a battery enclosure.
Using gas metal arc welding (GMAW) at Lincoln Electric Additive Solutions, they printed two stainless steel ER410 mould halves complete with internal features. This electric arc welding technique fuses layers of metal wire with precision, all while a shielding gas keeps things clean. A tailored toolpath strategy ensured the moulds remained strong but lightweight.
Once finished, the moulds underwent structural testing—and passed with flying colours. Not only did they meet the performance specs, but they did so with less material and a quicker turnaround than traditional moulds.
It was, in short, proof that additive manufacturing isn’t just feasible for high-performance production tooling—it’s a viable alternative for industries hungry for speed, cost-efficiency, and sustainability.
Scaling Up with National Support
This breakthrough didn’t happen in isolation. It’s the result of strategic investment and collaboration, all spearheaded by the DOE’s Advanced Materials and Manufacturing Technologies Office (AMMTO). Backing the project were not just ORNL researchers, but also experts like John Unser from Composite Applications Group, Peter Wang from ORNL, and Jason Flamm and Jonathan Paul from Lincoln Electric Additive Solutions.
The project was housed at ORNL’s Manufacturing Demonstration Facility (MDF)—a key hub for national innovation, where partners from across the U.S. come together to reshape the future of manufacturing.
“The MDF is a testbed for turning what-if scenarios into practical tools,” said one senior DOE official. “Whether it’s new materials, robotics, or smarter design workflows, our goal is to help American manufacturers remain competitive on the global stage.”
Unlocking the Potential of Composite Materials
One of the less talked-about benefits here is how 3D-printed moulds can accelerate the adoption of lightweight composite materials in vehicle design. By producing intricate, large-scale moulds faster and more flexibly, automakers can experiment more freely with advanced composites—such as carbon fibre or glass-reinforced plastics.
These materials are crucial in the transition to low-emission vehicles. Lighter cars mean better fuel efficiency and longer battery range. And with electrification now the name of the game, this could be a real game-changer.
Simply put, if the tools are faster and cheaper to make, the end products can evolve more quickly. That means better vehicles, built in less time, with fewer environmental trade-offs.
A Catalyst for American Manufacturing
Let’s not understate the broader economic significance either. By deploying large-scale additive manufacturing on American soil, the U.S. gains not just technological edge, but also manufacturing sovereignty.
It’s about shortening supply chains, cutting down emissions, and building jobs in advanced manufacturing. From Detroit to Chattanooga, this kind of innovation could ripple through the entire supply network, bringing with it revitalised factories, smarter infrastructure, and leaner production lines.
And it’s not just the automotive sector that stands to benefit. From aerospace to energy and even defence, the capability to quickly fabricate complex, durable metal components is transformative across the board.
Embracing a Smarter, Cleaner Future
The road ahead is clear: additive manufacturing is no longer a niche tool for prototyping or small-batch production. With real-world validation in hand, it’s ready for primetime.
From stainless steel battery enclosures to intricate aerospace parts, the digital foundry model—where design, simulation, and printing happen in lockstep—is set to become the new norm. And as research like this continues to demonstrate, the benefits go far beyond efficiency. We’re talking about sustainability, resilience, and the ability to outpace the challenges of tomorrow.
As Nycz succinctly put it: “This is how we build smarter, not just faster.”
