MacLean-Fogg Company (MFC) and the Fraunhofer Institute for Laser Technology ILT have reached a significant milestone in automotive manufacturing innovation. Together, they’ve created what is believed to be the world’s largest nearly solid, 3D-printed die-casting insert — weighing 156 kilograms (approximately 350 pounds). The insert will be used in the production of Toyota Europe’s Yaris hybrid transmission housing.
The tool was produced using Fraunhofer ILT’s advanced gantry-style, multi-laser Laser Powder Bed Fusion (LPBF) system and MacLean-Fogg’s proprietary L-40 tool steel powder. A hybrid production approach was chosen to align with Toyota’s cost efficiency goals.
“Using gantry-style printing with L-40 tool steel opens new possibilities for scaling metal additive manufacturing,” said Dr Magdalena Coventry and Dr Andrew Willett of Toyota Europe. “It enables shorter lead times, improved responsiveness, and exceptional insert performance—while extending maintenance cycles and maintaining competitive cost levels. We’re proud to help push the boundaries of what’s possible in modern manufacturing.”
MacLean-Fogg’s L-40 powder was engineered specifically for LPBF applications to provide superior hardness and toughness. These properties reduce cracking during production, even when processed at moderate preheat temperatures. Compared with traditional tool steels, L-40 minimizes the need for post-build heat treatment—shortening production timelines and accelerating delivery.
The L-40 tool steel developed by MacLean-Fogg offers a range of advantages that make it a breakthrough material for die-casting applications. Its design minimizes aluminum soldering on die surfaces, ensuring smoother production runs and reducing wear on the tooling. L-40’s robust composition provides nearly double the service life compared to traditional inserts, delivering enhanced durability and cost savings over time. In addition, the material requires less frequent maintenance, leading to improved uptime and greater manufacturing efficiency.
Another notable benefit of L-40 is its environmentally conscious formulation. The material is entirely cobalt-free and contains only a minimal amount of nickel, supporting sustainability goals and aligning with global efforts to reduce the use of critical raw materials. These attributes make L-40 a compelling option for automakers and suppliers focused on both performance and environmental responsibility.
“Toyota challenged us to apply L-40 on a much larger scale,” said Dr Harald Lemke, Director of Product Development at MacLean-Fogg. “That meant overcoming new engineering hurdles, such as ensuring uniform gas flow conditions throughout significantly larger build volumes.” The project required innovative process optimization and close collaboration between MacLean-Fogg and Fraunhofer ILT to meet Toyota’s exacting standards for performance and cost efficiency.
To address these technical demands, Fraunhofer ILT utilized its cutting-edge gantry-type Laser Powder Bed Fusion (LPBF) machine. This advanced platform integrates five lasers and supports parts exceeding 50 centimeters in side length, maintaining chamber temperatures up to 200°C. Such capabilities are critical for manufacturing large-format die inserts with precise internal cooling channels and complex geometries that cannot be achieved with conventional machining methods.
“This project represents exactly why we developed our gantry system,” explained Dr Niklas Prätzsch of Fraunhofer ILT. “The L-40 material makes it possible to perform large-scale additive manufacturing at lower operating temperatures without sacrificing quality or mechanical strength.” The combination of L-40’s metallurgical stability and the gantry system’s scalability demonstrates a new frontier in metal 3D printing for industrial applications.
Following this success, Fraunhofer ILT and MacLean-Fogg intend to expand the technology into additional manufacturing domains. Future projects will focus on structural die-casting tools, giga-casting applications, and other large-scale forming tools used in both hot and cold processes. These developments reflect the automotive sector’s broader objectives—lightweighting, accelerated design-to-production timelines, and stronger regionalized manufacturing ecosystems.
MacLean-Fogg will showcase these innovations at two major upcoming events. Dr. Harald Lemke will present the findings at the NADCA Die Casting Congress & Exhibition on October 7 in Milwaukee, USA. Additionally, the company will exhibit its latest advancements in additive manufacturing at Formnext 2025, taking place from November 18–21 in Frankfurt, Germany (Hall 11.0, Booth A58). These platforms will highlight how advanced materials like L-40 and next-generation LPBF systems are redefining the future of die-casting technology.
Headquartered in Mundelein, Illinois, MacLean-Fogg Company is a privately held organization serving the global automotive and industrial sectors for more than a century. With 17 facilities worldwide and over 2,000 employees, the company designs and manufactures precision fasteners, engineered components, and advanced tooling for leading OEMs and Tier 1 suppliers.
Recognized for innovation and quality, MacLean-Fogg continuously advances metalworking and additive manufacturing to deliver scalable, high-performance solutions for die casting, prototyping, and production. Guided by values of integrity, customer focus, and long-term stewardship, the company supports key industry shifts toward lightweight design, electrification, and stronger local supply chains.
