All of the previous methods of rapid tooling involve the indirect production of a master pattern from which the tool is produced.

One of the concerns of producing a tool is the time it takes to produce and finish this pattern. Also, replication techniques, such as these can lead to inaccuracies. Ultimately, companies want to produce the tooling directly, although most of the direct tooling methods are not without limitations.

Using additive “layer manufacturing” techniques, it is possible to include additional features in the tool that are impossible to achieve with conventional tooling techniques. The most significant of these is conformal cooling (or heating) channels that allow the cooling or heating of the tool at points where it is required – not only where the channels can be conveniently drilled, as in conventional cooling. Investigations have shown that conformal channels can cut injection mold cycle times by up to 40 percent. The total methods include Direct AIM tooling, SLS RapidSteel, Copper Polyamide Tooling, Direct Metal Laser Sintering, Laminated Tooling, LENS, Controlled Metal Build-up (CMB), Prometal