Using Additive Manufacturing to Improve Performance and Business Case for Lathe Chuck Jaws

For “one-off” and low production volume projects, metal additive manufacturing (MAM) offers many advantages compared to traditional metal-forming and machining technologies, including superior design freedom, short lead-time from concept to build, and zero tooling investment. One product family that has benefited from these technical advantages is work-holding fixtures for production machining, specifically chuck jaws for turning. In addition to offering cost effective and rapid design iterations for improved launch readiness and program cost management, MAM technology also enables process capability improvements that cannot be achieved by chuck jaws produced by other means. Primarily beneficial for thin-walled components, the light-weight chuck jaws net significantly tighter inner diameter circularity compared to turning with conventional chuck jaws. This paper details a case study spotlighting the differences in design, build, lead-time, cost and machining process capability between lightweight chuck jaws produced from additive manufacturing and traditional chuck jaws produced from tool steels.