US Patent 10029305 Segregated multi-material metal-matrix composite tools

A method for fabricating an infiltrated metal-matrix composite (MMC) tool includes positioning at least one boundary form within an infiltration chamber of a mold assembly and thereby segregating the infiltration chamber into at least a first zone and a second zone. Reinforcement materials are deposited into the infiltration chamber and include a first composition loaded into the first zone and a second composition loaded into the second zone. The first and second compositions are then infiltrated with at least one binder material to provide the infiltrated MMC tool with differing mechanical, chemical, physical, thermal, atomic, magnetic, or electrical properties between the first and second zones.