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3D Printing the Future of E-Mobility Tools

3D Printing the Future of E-Mobility Tools

3D Printing the Future of E-Mobility Tools

Kennametal’s 3D printed stator bore tool meets accuracy, roundness, and surface finish requirements of hybrid and electric vehicles.

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 centres 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 aluminium motor body boring.

“The main bore, which houses the stator of an electric motor measures approximately 250 mm in diameter (9.84 in) and approximately 400 mm (15.74 in) in length, with a smaller bearing bore at the bottom,” says Harald Bruetting, Manager, Program Engineering, at Kennametal. “When manufactured using conventional means, a reamer for this type of application would weigh more than 25 kg (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.

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