Specialized Wrench Tools: Faster, Stronger, and Cheaper with Additive Manufacturing at Cyient

Challenge: Expensive, Hard-to-Machine Parts with Durability Issues

Cyient faced a challenge in producing specialized wrench tools that were both difficult and costly to machine. The existing approach also had durability concerns, making it clear that a more efficient, reliable, and cost-effective solution was needed.

Rapid Design, Data Prep, and AM Campus Collaboration

The project began with a quick design session followed by a rapid data-prepping session to prepare the parts for production. An event at the AM Campus brought together post-processing, hands-on evaluation, and shared learning.

Using Laser Powder Bed Fusion (LPBF) technology, the team was able to produce complex geometries that would have been difficult — or impossible — to manufacture using traditional methods.

Results: Lower Cost, Higher Strength, Faster Delivery

Additive manufacturing proved its value in multiple ways. The printed wrench tools were significantly cheaper to produce (from €X down to €Y), torsionally stronger as confirmed with a quick torque wrench test, and much faster to deliver compared to conventional machining.

Through the process, Cyient’s designers gained important insights into optimal clearances and the potential of LPBF to create robust, complex components with ease.