Hybrid tooling

To get maximum performance at the lowest cost, we’ve developed the hybrid method of constructing a LaserCusing core with conformal cooling.

Cooling is always troublesome at the top of cores where cooling channels must be closed, preferably without any seam or Ampco/steel cap. Usually the base of a core can be made most easily by a conventional method such as milling or turning. You simply provide this base to us fabricated oversize by 0.1" (0.3mm) on which we perform the additive LaserCusing process. Note that you should always harden the base before delivering it to us.

This base is then placed into the LaserCusing machine and we add material to its top surface. Although built in this hybrid way, a core is still physically made from a single rugged piece of tool steel. We can harden the material deposited by LaserCusing to about 52-54 HRC if required, and then we’ll send the part right back to you.  All you then have to do is a small amount of finishing to fit it into the mould.

The pictures on the right show the hybrid method from initial CAD design to a finished, hardened core for a packaging product. This method of manufacturing a mould insert is also explained under the menu item 'How it works...'