## 2 Materials and Methods
### The Cutting Process of the Specimens  
To minimize burr formation, the correlation established by [PERSON] can be utilized during the design of the polyurethane-padded tool to determine the minimum height of the cutting edge that ensures optimal burr formation [48]. This relationship is illustrated in Figure 5.  
The optimal height of the cutting die (\(H\)) to minimize burr formation can be calculated using Equation (1). \[H=3\bigg{(}1+\frac{A_{11,3}}{100}\bigg{)}\sqrt{s}\;[\text{mm}] \tag{1}\]  
where s is the thickness of the plate (sheet) in mm and \(A_{11.3}\) is the percentage strain at breakage related to \(L_{o}=10\cdot d_{0}\), measuring the basis (base) length (\(d_{0}\) represents the original diameter (or thickness) of the sample or specimen used in the tensile test before any deformation occurs) [49; 50]. \begin{table}
\begin{tabular}{c c} \hline \hline \multicolumn{1}{c}{**Technical Specifications/Parameters**} \\ \hline Type/model & SP100E \\ Max. loading capacity [t] & 100 \\ Stroke length [mm] & approx. 280 \\ Piston size in diameter [mm] & 68 \\ Maximum working width [mm] & 810 \\ Working height [mm] & approx. 60-950 \\ Minimum height [mm] & approx. 400 \\ Overall dimensions (length \(\times\) width \(\times\) height) [cm] & \(195\times 115\times 50\) \\ Height adjustment & at 7 points \\ Shipping dimension (length \(\times\) width \(\times\) height) [cm] & \(200\times 115\times 52\) \\ Shipping weight [kg] & 630 \\ \hline \hline \end{tabular}
\end{table} 
Table 7: Az EZ-TOOLS SP100E data table. Figure 4: The EZ-TOOLS SP100E workshop press. Figure 5: Calculation method of the tool height (\(H\)) considering the conical angle (\(\alpha\)). Using the Komarov tooling arrangement [48], the compression tools are commercially available 5 mm thick rubber sheets (80 ShoreA) stacked 50 mm thick. The cutting speed was not relevant due to the compression of the bases, but the machine speed was 20 mm/min. Based on this correlation, the required cutting edge heights for the Al99.5 sheet materials with thicknesses of 0.22 mm and 0.3 mm are listed in Table 8. No literature data is available on the angle of under-grinding, and arbitrary values are generally recommended. For the experiments, a uniform under-grinding angle of 3\({}^{\circ}\) was applied. The printing orientation (i.e., the angle between the printed object and the printing bed) can influence the mechanical properties of the model. To investigate this effect, the cutting edges for the polyurethane-padded punching tool were printed with three different orientations: 0\({}^{\circ}\), 15\({}^{\circ}\), and 45\({}^{\circ}\) relative to the plane of the print bed. Adjusting the wall thickness can also affect the mechanical properties of the model. Increasing the wall thickness makes the model progressively stiffer. For the cutting edges of the polyurethane-padded punching tool, three wall thickness values were set for each printing orientation, aiming to determine the optimal configuration for punching thin aluminum sheets. These wall thicknesses were set to 2 mm, 4 mm, and 6 mm, as shown in Table 9.  
After printing, the brim (a technological addition to enhance adhesion) had to be removed from the edges of the printed tools. This feature improves adhesion to the printer bed. Furthermore, the supports had to be removed from the underside of tools printed at 15\({}^{\circ}\) and 45\({}^{\circ}\) orientations. These supports were necessary to provide backing for the initial layers deposited in midair. The measurement process was carried out using the GOM ATOS optical measurement system following post-processing steps. Initially, the 3D-printed cutting edges were digitized in their as-printed state (referred to as the 0-state) to serve as reference data. Afterward, three sheets were cut, followed by a second round of scanning. Subsequently, an additional three sheets were cut, and the process concluded with a third round of measurement. Thus, each test specimen involved six cutting operations.