Fabrication of laminate structures using direct metal deposition

Abstract

A laminate material composite structure is fabricated using a laser-based direct-metal deposition process to provide unique physical and mechanical properties. The relative difference in physical properties such as thermal conductivity between dissimilar pure metals or metal alloys provides the ability to deposit highly conductive materials having a low level of porosity using the DMD laser-based process. The proximity of a pure metal or metal alloy which has relatively high mechanical properties, compared to that of thermally conductive material, provides the structural strength, hardness and wear resistance required of mold materials. The combination of physical and mechanical properties associated with the laminate material composite structure provide thermal management benefits which result in a reduction in molding process cycle times and improved part quality.