Abstract
An innovative injection mold making and cooling approach using a hybrid additive and subtractive machine tool is proposed in this paper. Approximated mold geometry is quickly formed using prefabricated blocks. Directed Energy Deposition (DED) followed by finish milling is then used to form the continuous free-form surface of the mold cavity. The innovative technique enables quick fabrication of a mold with a conformal cooling channel resulting in a dramatic improvement in cooling performance of the mold. A mold prototype was fabricated and the performance was evaluated compared to a mold fabricated by the traditional subtractive machining method.
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