3D Printed Composite Tooling

Composite tooling includes molds, forms, and fixtures used to shape and process composite materials like carbon fiber. 3D printing allows manufacturers to create these tools faster, more affordably, and with greater design flexibility than traditional machining. 

Printed composite tools are used for layup molding, trimming, assembly, and inspection. FDM® produces durable, lightweight tooling ideal for large-format parts, while SLA provides high-resolution surfaces for precise molding and pattern making.  

3D printed tooling significantly reduces: 

• Lead times – from weeks to just days 
• Material waste – no subtractive machining 
• Tool weight – easier handling, improved ergonomics 
  It also enables rapid iteration and custom geometry without retooling. 

• FDM® – Large-scale, heat-tolerant tools with rugged thermoplastics 
• SLA – Smooth, high-resolution tools and masters ideal for surface-critical applications 

In most cases, composite tools can be printed in just a few days, compared to several weeks using traditional machining. This helps accelerate production timelines, reduce downtime, and increase responsiveness to design changes.

Ideal applications include: 

• Layup molds for hand or vacuum-formed composites 
• Trim and drill fixtures 
• Assembly tools and templates 
• Master patterns for composite part forming  

Identify tooling applications where time, cost, or complexity is a barrier. Then consult with a Stratasys expert to explore printable designs and determine whether FDM® or SLA is best suited to your tooling needs. 

1. What is composite tooling?  

Composite tools refer to the molds used to create composite materials. These tools are known for their stiffness, durability, and their ability to retain their shape under the high temperatures of the molding process. 

2. How does 3D printing benefit composite tooling? 

3D printing offers several benefits for composite tooling, including reduced lead times, cost efficiency, design flexibility, and simplified tooling processes. 

3. What materials are used in 3D printed composite tooling?  

Common materials used in 3D printed composite tooling include high-performance thermoplastics, carbon fiber-reinforced polymers, and other advanced composites that can withstand high temperatures and mechanical stresses. 

4. Can 3D printed composite tools be used for high-temperature applications?  

Yes, 3D printed composite tools can be designed to withstand high temperatures, making them suitable for demanding applications in industries such as aerospace and automotive. 

5. What are sacrificial tooling techniques in 3D printing?  

Sacrificial tooling techniques involve creating a tool that is designed to be easily removed or dissolved after the composite part is formed. This simplifies the manufacturing process, especially for hollow parts, and reduces the risk of damage to the final part. 

6.How does 3D printing reduce production costs for composite tooling?  

By eliminating the need for complex molds and additional tooling, 3D printing reduces overall production costs. This is particularly beneficial for low-volume production and high product mix scenarios.