Researchers 3D Printed 2-Ton Industrial Mould

Oak Ridge National Laboratory and Boeing successfully produced a large-scale steel tool using wire-arc additive manufacturing.

Updated on Sept. 29, 2026 in Materials Science

A large robotic arm builds a massive steel die mould layer by layer in a high-tech industrial laboratory setting. — Oak Ridge National Laboratory and Boeing successfully manufactured a 2-ton industrial steel mould using wire-arc additive manufacturing to improve aerospace production speed and costs. AI Illustration. Upload story photo >

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Oak Ridge National Laboratory and Boeing have manufactured a 2-ton, 6-foot by 4-foot stamp form die mould using wire-arc additive manufacturing. This research-stage effort aims to validate whether 3D-printed, thermally controlled moulds can outperform traditional manufacturing in speed and cost.

Why it matters

This development addresses the manufacturing bottlenecks for large-scale composite components, potentially reducing costs and lead times for aerospace projects. The integration of temperature control within the mould structure could expand the use of 3D printing into energy and automotive sectors.

The mould measures 6 feet by 4 feet and weighs 2 tons, constructed from a mix of mild and stainless steel. Engineers integrated curving channels directly into the geometry to facilitate precise temperature control.

The players

Oak Ridge National Laboratory

A Department of Energy national laboratory focused on large-scale additive manufacturing research and advanced materials science.

Boeing

A global aerospace company integrating advanced composite manufacturing for commercial and military aircraft.

Baker Industries

A specialized manufacturing facility in Michigan that provides annealing and final precision finishing for large industrial tools.

The details

The team utilized a wire-arc additive manufacturing system, which employs a robotic arm and welding torch to melt metal wire layer by layer. To manage the residual stress and thermal warping inherent in large-scale metal 3D printing, engineers performed 32 computer simulations. They also incorporated temporary structural ribs to maintain stability during the build process before final annealing and finishing by Baker Industries.

September 29, 2026: Article publication date.

The Tech Race

This project directly supports the goals of NASA's Hi-Rate Composite Aircraft Manufacturing program, which seeks to accelerate aerospace production speeds. The successful 3D printing of this mould marks a shift toward replacing traditional, slow, and expensive subtractive tooling methods with additive alternatives.

This technology is currently in the research phase and will initially impact aerospace manufacturing workflows for large composite structures. Widespread adoption remains dependent on future scaling in the automotive and energy industries.

The takeaway

This successful 2-ton build demonstrates that computer-aided stress simulation can effectively manage the warping challenges of large-scale wire-arc printing. Watch for future performance benchmarks from the Hi-Rate Composite Aircraft Manufacturing project to see if these moulds sustain industrial durability.