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.Mechanical Engineerin
