Master molds for replication techniques are normally made by machining processes. As a consequence of this subsequent modifications are expensive and complex. Therefore new technologies are desired, especially due to the fact that each design requires an individual mold. Printing technologies enable the direct transformation from digital data into printed material [1]. By the choice of a suitable printing medium and a printing technology the direct fabrication of structures is possible. An additional benefit is the ease of modification and customization of mold and dies without the need of tools, tooling equipment or time-consuming machining processes [2]. The material properties of Hot Melt Inks (HMI) simplify the combination with existing fabrication techniques. Their compatibility predestines them for applications with casting processes, e.g. by two-component silicon-based organic polymers or electroplating [3]. Two different fabrication approaches for mold and die manufacturing are introduced. The first one is a printing process of HMI structures for direct mold fabrication. Here the printed structures are used directly as the negative form for a casting process. The second one is a printing process for the fabrication of buried structures and multi-layers. The HMI forms are completely buried by this casting process and are subsequently removed.
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