3D Welding and Milling for Direct Prototyping of Metallic Parts

Welding has been used for the direct fabrication of metallic prototypes and prototype tools by several research institutes. Since welding alone is not able to deliver the accuracy and the surface quality needed for prototype tools, especially for injection molds, a combination with conventional machining is necessary. In this paper, welding and 5-axis milling are combined together for the direct fabrication of metallic parts. For welding, conventional CO2 arc welding is used. Test parts with conformal cooling channels an~ undercuts demonstrate the technological potential ofthis process combination for rapid tooling applications.