Foundry Corporate News Topic Testing, measuring & Quality Control

Cost-effective repair thanks to laser deposition welding

Increase in productivity and service life for the repair and new production of die casting molds

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In the past seven years, laser deposition welding has emerged as an excellent technology for the repair and coating area in many target industries. Every other industrial customer purchases the LASERTEC 65 3D hybrid because of the cost-effective repair options. The recently introduced LASERTEC 125 3D hybrid provides room for larger components. 

Die casting molds with up to 3 times longer service life and up to 30% improved cooling characteristics
The LASERTEC 3D hybrid series provides advantages compared to current solutions on the market, particularly with regard to the repair of costly die casting molds for the production of aluminum pressure die cast parts. Worn tool molds can be milled off at the neuralgic points, and then be automatically repair welded. Thanks to the hybrid concept, the laser head and the milling tool can be changed and replaced any number of times.

“This way, the die casting molds can also be milled to their final dimensions in one machining cycle”, says Patrick Diederich. He illustrates the added value with the example of several reference customers from the area of aluminum die casting: “Up to now, the die-cast cores had to run through a multi-day repair process. They can now be put back into operation within one shift thanks to powder nozzle technology.”

This alternating process from subtractive and additive machining is the main advantage of the LASERTEC 3D hybrid series. It does without complex parts handling of the tool molds weighing up to 2,000 kg and enables complete machining in a single setup. Tooling and setting up times are thus reduced to a minimum, so that the repaired die casting mold can be used up to 90 percent faster. Furthermore, the tool service life increases by up to 300 percent with the machining process from DMG MORI. The reference customer Toyota confirms this rather impressively with the three times longer service life of its die-cast cores compared to the previous manual repair welding. Another potential for optimization is the use of multi-materials. For example, the mold core can be produced with an alloy which has a 30 percent higher thermal conductivity than the tool steel in the top layer. This increases the cooling rate in the die casting process and consequently the output. 

WEBINAR  - In German language:
Kosten- und Durchlaufzeitreduktion in der Herstellung und Reparatur von Druckgussformen
DO 18.06.2020, 10:00 - 11:30 Uhr

Register here:


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