Patent ID: 8062715

Claim:
A method of fabricating a die or mold, comprising the steps of: depositing a first metallic alloy or ceramic/metal composite on or within a gate portion of a die or mold using a laser-assisted direct metal deposition process of the type wherein a powder is fed to a melt pool under closed-loop feedback control, a gate portion being defined as an entrance through which material is introduced into the die or mold; depositing a second metallic alloy or ceramic/metal composite on or within portions of the die or mold other than the gate portion(s) using the closed-loop, laser-assisted direct metal deposition process; and wherein: the strength or impact resistance of the first metallic alloy or ceramic/metal composite is greater than the strength or impact resistance of the second metallic alloy or ceramic/metal composite, or the thermal or wear resistance of the second metallic alloy or ceramic/metal composite is greater than the thermal or wear resistance of the first metallic alloy or ceramic/metal composite.