Hello,
Thanks for the compliments and encouragement!
To answer some questions:
1. I made several prototypes but the tool would most likely last for quite a while in my application. For that process, I create models and flat patterns in Solid Edge, then I create the G code in V Carve Pro and run the flat patterns on my Camaster Stinger CNC router. I'm typically bending smaller gages of 5052 aluminum and my vise is 5" wide so I'm not really running into high clamping forces. I do now have a 20ton press so I might see what I can cook up for that.
2. One of tricks I learned from the video is to set up the 3D print with a larger number of perimeters (thicker skin on the tool) and also increase the infill. I typically run about 15% infill for small parts but for the tool I think I ran it up to 40%.
3. I imagine someone out there is trying out 3D metal printing and it might be possible to make them so they key together on the press brake.
4. Markforged makes 3D printers that have carbon fiber reinforcement and I bet it can create even stronger parts.
Here is another cool video where 3D prints are used to form a shoe for a sawzall. I like it because he goes through the iterations needed to come up with his final idea.
Another thought I had was to use 3D prints to create forming tools for screen type or expanded metal parts - (like speaker grills or microphones). It would take some work to deal with springback etc. but could be a fun project. I've seen people do something similar with forming tools made from wood.
Kyle