Abstract
This study establishes a systematic and reproducible workflow for the topological optimization (TO) of milling tool bodies with indexable inserts, specifically designed for metal Fused Filament Fabrication (FFF). Grounded in Design for Additive Manufacturing (DfAM) principles, the workflow enables the development of high-performance tool geometries with advanced features while allowing direct comparison with conventionally manufactured counterparts. By leveraging iterative design knowledge, the proposed methodology enhances scalability and repeatability, reducing development time and supporting rapid adaptation across different tool types. Additive manufacturing (AM) disrupts traditional manufacturing constraints, permitting the integration of novel design elements such as optimized internal coolant channels directed toward the insert edge and substantial weight reduction, thereby contributing to more sustainable material usage. The workflow successfully integrates coolant channel design within a TO-based framework, producing reproducible results that meet machining performance requirements with only 80% of the original tool mass. These findings highlight the disruptive potential of AM to enable innovative and sustainable solutions for industrial cutting tools, reinforcing the role of DfAM in advancing tool design strategies.
Biography
José Costa, EUR ING, holds a Ph.D. in Metallurgical and Materials Engineering and has a decade and a half of experience bridging advanced manufacturing research and industrial application. Specialized in metal Additive Manufacturing, his expertise includes project management, process optimization, and technology integration. In addition to his technical background, José completed advanced postgraduate studies in Services Management at the Faculty of Economics of the University of Porto (FEP), and MSc. and BSc. in Metallurgical and Materials Engineering, equipping him with a solid foundation in organizational strategy and innovation leadership. His profile reflects a combination of engineering depth and strategic insight.
