The overarching objective of this work is to develop a rapid manufacturing process that produces plastic pattern tooling. The process is considered a hybrid approach to tooling because it will involve bonding sheets of plastic through ultrasonic welding and machining the desired features into each layer. In order to realize this new system, there are several sub objectives that are satisfied in this work; 1) the development and refinement of the bonding process, 2) process planning methods for inter and intra slab processing and 3) machine integration and testing. In this work a method is presented for determining energy director location. A pattern tool was created using this method for energy director location to verify the entirety with process planning, ultrasonic welding, and machining integrated together.