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Techniques for rapid prototyping and tooling are limited for size and in the materials that can be used. A new method of Metal Layer Object Manufacture (MELOM) tool manufacture is described, whereby individual layers are bonded using diffusion soldering. The method uses the silver-tin system, but copper-tin is equally suitable. It offers benefits such as speed of production for large-scale prototype tooling.

The die casting industry is under increasing pressure to improve production rates to enable greater productivity. Employing conformal cooling channels could potentially improve a die performance through the reduction of solidification times. The paper reviews simulated solidification results from a traditional cooling channel design and a conformal cooling channel design. The paper continues by describing the construction of bonded laminate insert with integrated cooling channels. Casting trials were conducted using the inserts to validate the simulated results. Work to date has demonstrated the ability to manufacture laminate inserts quickly, the accuracy of finite element analysis and the importance of designing conformal cooling channels. [ABSTRACT FROM AUTHOR]