Hybrid Rapid Prototyping

This part, a complex-finned aluminum heat exchanger, was created using a combination of 
abrasive waterjet cutting, friction stir lap welding, and CNC machining.

Step 1: Individual layers are cut from large sheets using abrasive waterjet cutting.

Step 2: The first layers are joined using friction stir lap welding.

Step 3: Additional layers are added until the full height is reached.

Step 4: The center bore is then machined to the final size.

The completed part.