ELIMINATE SIZE LIMITS FOR 3D PRINTED STEEL MOLDS & PARTS!

 Synergy’s Mechanical Joining + Laser Cladding

· World’s first fully warrantable welding/joining solution for 3D printed steel injection molds of any size

·  Developed specifically to match or outperform conventionally machined steel tooling

·  Enables rapid, scalable production of complete 3D printed steel tools

Distributed Manufacturing Model

· Distributed 3D printing network allows all mold sections to be printed simultaneously across multiple machines

· Parallel production drastically reduces lead time compared to conventional or single-printer approaches

Technical Highlights

· Up to 95% mass reduction through advanced light-weighting strategies

· Conformal cooling & heating channels integrated directly into the mold steel for optimized thermal management

· Mechanical joining features (e.g., dovetails) designed into each mold section for strong mechanical interlocking

· Laser cladding applied post-assembly to permanently trap mechanical features and hermetically seal joints

Benefits Delivered

· Faster lead times – Tool production in days or weeks possible if required, not months

· Cost-competitive with conventionally machined steel molds

· Superior thermal performance in-mold, enabling:

Faster cycle times

More consistent part quality

Improved molding of challenging geometries

· Reduced scrap rates through better thermal control and dimensional stability

· Lower machine utilization costs due to shorter cycles, reduced mold weight, and higher uptime

· Extended tool life – up to 1 million cycles, depending on application

· Polishable to A2 finish and texturable like conventional P20/H13 molds