The Metal Powder Application (MPA) process represents an innovative fusion of five-axis milling and cold spray deposition, offering mold builders and manufacturers a groundbreaking approach to hybrid manufacturing. Unlike traditional additive methods that rely on melting or high temperatures, the MPA process adds material to a workpiece at low temperatures using a cold spray technique. This eliminates thermal stress, preserves the integrity of surrounding materials, and opens the door to new possibilities in design and functionality.

One of the most compelling applications of the MPA process is in mold tooling, where conformal copper regions can be added to enhance cooling performance, significantly reducing cycle times. Additionally, the low-temperature process allows for the creation of complex internal geometries, functionally graded materials, and the embedding of components such as sensors directly within the workpiece.

Hermle, a leader in high-precision milling systems, has integrated this hybrid manufacturing capability into its portfolio through its German subsidiary, which specializes in the MPA process. By combining precision milling with cold spray deposition, Hermle enables manufacturers to achieve unprecedented design flexibility and functionality without the drawbacks of high-heat additive methods.

At IMTS 2024, Hermle showcased the MPA process for the first time, presenting its potential through various case studies. This technology not only expands the limits of manufacturing but also paves the way for entirely new applications where high-temperature methods were previously unsuitable.

• Hermle’s Metal Powder Application (MPA) Process