To manufacture rapid metal tools ，an innovativative method based on raid prototyping and high pressure spraying technologies is proposed in this study.The Sn-Bi metal alloy with low melting pount and small thermal shrink was used as the spraying materials. Applying an elecric heated device and high pressure boost pump，the melting Sn-Bi Alloy went through a small spray nozzle and atomized into semi-melting minute particles.the atomized particles are then deposited and integrated on the surface of intermediate silicone rubber mold，which is made from the rapid prototyping(RP)system and are successfully used to manufacture rapid wax injection mould.Using the thermal spraying system to manufacture rapid metal mold. the surface quality and the dimensional accuracy of the spray mold is excellent and the fabricaed cycle time is short.