Boeing and ORNL Produced Large 3D-Printed Steel Die
Manufacturers of large components may soon use additive methods to replace traditional casting and milling processes.
Updated on Sept. 26, 2026 in Manufacturing
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Boeing and Oak Ridge National Laboratory (ORNL) successfully produced a 2-ton steel Stamp Form Die using wire-arc additive manufacturing. This project signals a potential shift in industrial tooling fabrication for aerospace and automotive sectors.
Why it matters
The project aimed to reduce production lead times and costs associated with industrial molds, which are traditionally complex and expensive to fabricate. By leveraging additive manufacturing, companies could simplify supply chains for heavy structural components.
The completed mold measures 6 feet tall by 4 feet wide and weighs nearly 2 tons. Production involved 32 simulation iterations to mitigate metal distortion before reaching the final design.
The players
Boeing
A global aerospace company that designs and manufactures commercial and defense aircraft, focusing on large-scale production.
Oak Ridge National Laboratory
A federal research institution that conducts large-scale technology development and industrial materials research.
Baker Industries
A contract manufacturer specializing in complex fabrication, stress relief annealing, and finishing for industrial components.
The details
The Arc-1 system at ORNL uses a robotic arm equipped with a welding torch to melt wire and layer metal to form the tool. The process requires careful thermal management, utilizing temporary structural ribs and extensive computer modeling to prevent residual stress. Following the print process, Baker Industries performed critical stress relief annealing and final fabrication to ensure the tool's structural integrity.
Timeline
September 26, 2026: Article publication date.
Market Landscape
This project builds on the adoption of wire-arc additive manufacturing as an alternative to traditional subtractive machining. It follows a growing trend of replacing heavy casting methods with layered deposition for specialized aerospace and energy infrastructure.
Manufacturers of high-rate thermoplastic structures should monitor this additive process as a potential method to shorten tool lead times. Operations managers should evaluate whether their upcoming project cycles can benefit from simulation-led additive fabrication.
The takeaway
Large-scale additive manufacturing allows for the creation of complex tools with integrated cooling channels that are difficult to machine. Review your current fabrication lead times to determine if additive techniques could replace existing casting or milling workflows for large molds.
Further reading
For more on industry shifts, visit the Manufacturing section.
Source note: This article includes information reported by 3D Printing Industry.
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