Weight Reduction and Structural Optimization of a Face Milling Cutter Using DfAM

This study explores the application of design for additive manufacturing (DfAM) to modify the design of a face milling cutter, with the aim of reducing its weight. Conventional manufacturing methods often limit design flexibility, particularly for hollow shapes and internal channels, while additive manufacturing offers greater design freedom. Using topology optimization, which removes low-stress regions, the face milling cutter’s weight was reduced by 36.1%. The face milling cutter was produced using a powder bed fusion (PBF)-based metal three-dimensional printer, followed by material verification, post-processing, and structural analysis. The results confirm the feasibility of weight reduction without compromising structural integrity, demonstrating the potential of DfAM for efficient, high-performance tooling design.