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Case Study / Mold Repair VIDEO Access video at end of article. By Christina M. Fuges Scott Mesick has been micro-TIG (tungsten inert gas) welding for the moldmaking industry since 1980. He launched Erie, Pennsylvania-based Micro Tool Welding (MTW) in 2003 and has since led the company in its tool and die welding specialization. MTW is strategically located about equal distances from Cleveland, Pittsburgh and Buffalo, which enables the company to quickly serve its tool and die, medical, aerospace and power generation customers across the country. The 4,400-squarefoot facility has a temperature-controlled environment that includes micro-TIG and micro-laser welding labs. "Our experience and knowledge combined with the latest technology has allowed us to become leaders in the micro-welding industry," Mesick says. "We have combined the advanced science of laser technology with the experience in tool and die repair." Laser-focused on Quality and Speed MTW faced several challenges after it was established, including reaching into areas that cannot be reached by micro-TIG welding, being able to apply small weld deposits on aluminum and copper alloys, and keeping the heat-affect zone (sink) to a minimum. Adding micro-laser welding to the company's capabilities would help address these challenges. And since MTW is known for its quick turnaround times—often same-day—Mesick wanted to add more laser capabilities to serve his customers even faster. Laser-welded four side walls of the pocket and re-established the rib on the I.D. of the hole. 18 MoldMaking Technology December 2013 Photos courtesy of Micro Tool Welding. Business Booms with Advanced Micro-Laser Welding Capabilities Using the most advanced laser welders has allowed Micro Tool Welding to achieve minimal to undetectable weld sink and distortion. And, the laser movement is mechanical, making it capable of providing a straight and consistent weld bead profle. Additionally, these machines offer the ability to weld close to standing features without damage to surrounding areas; and the laser technician is able to deposit weld uniformly and accurately. Mesick visited several laser welder manufacturers before making his final purchasing decision. "After reading a 2007 case study in MoldMaking Technology on O.R. Laser USA, a laser welder manufacturer based in Elk Grove Village, Illinois, I knew its system would best suit my applications." He immediately flew to Chicago to visit the company. "I took a part with me that was almost impossible to microTIG weld and gave it to the technician," Mesick recalls. "With no hesitation he took the part and welded it. I was totally amazed. That is what sold me. It was a super-small insert from a mold that you had to pick up with tweezers. He had to weld in a hole in between two standing legs sticking up on the part, and he had to reach down in this hole. I was totally baffled at how he could do that—and it took him about 10 minutes." Mesick purchased a 200-watt laser welder in 2007 from O.R. Laser. He also added a 300-watt laser welder in 2010 so Added 0.080 inch per side on a copper alloy core. Laser-welded 0.020+ inch on a surface that was off location.