Additive manufacturing of metal cutting tools: toward synergistic innovation in design, materials, processes, and performance

Abstract

Additive manufacturing (AM) is revolutionizing the fabrication of high-performance metal cutting tools by transcending the geometric and material constraints of conventional methods. This study establishes a design-process-material-performance integration framework to overcome critical challenges in AM-enabled tool development. Through systematic review and analysis, three innovation pathways are proposed: i) novel design methodologies leveraging topological optimization and bio-inspired structures, ii) development of high-performance materials, and iii) process optimization strategies for micro-structure regulation, densification control, and hardness–toughness balance. The analysis reveals persistent limitations in current AM tool technologies; these include material defects induced by process instabilities, post-processing bottlenecks, lack of standards, and cost barriers hindering industrial adoption. Frontier research directions for propelling future advancements are delineated as follows: AI-driven full-process development, smart tool integration with embedded sensors, and nano-reinforced composite materials. Concurrently, engineering-oriented priorities should emphasize user-specific design customization, process–material compatibility studies, and quality assurance protocols for AM tool standardization. This work provides theoretical frameworks and actionable roadmaps to bridge the gap between academic exploration and industrial implementation of AM-based cutting tools.

Graphical abstract

Keywords

additive manufacturing / metal cutting tool / design innovation / smart manufacturing

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