Method for manufacturing mold

Abstract

To provide a method for constructing molds and / or tools formed from non-porous materials such as metals for plastics manufacturing.SOLUTION: A part formed by an additive manufacturing process includes a plurality of layers, including a first layer and a second layer, the first layer and the second layer laminated along a laminating direction, and a work surface formed on a top surface of the first layer and a top surface of the second layer. The part also includes a first through hole formed in the first layer, a second through hole formed in the second layer (the second through hole being at least partially aligned with the first through hole), and a wall extending from the first through hole to the work surface.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] Technical Field Aspects of the present disclosure relate to systems and methods for creating components. In some cases, aspects of the present disclosure relate to methods and systems for creating components (patterns, molds, similar products, etc.) via techniques or processes similar to 3D printing processes with layering. These techniques or processes enable the manufacture of low-cost molds or tools without using a 3D printer in at least some embodiments.

Background Art

[0002] Background Additive manufacturing techniques and processes generally involve the layering of one or more materials to create net or near-net shape (NNS) objects, as opposed to subtractive manufacturing methods. "Additive manufacturing" is an industry standard term (ASTM F2792), but additive manufacturing encompasses manufacturing techniques and prototyping techniques known by various names, such as freeform fabrication, 3D printing, rapid prototyping / tooling, etc.

[0003] Some additive manufacturing techniques use large 3D printers that can manufacture very large parts, molds, patterns, etc. These parts can be made, for example, from fiber-reinforced thermoplastic materials. One way to manufacture these parts is to use a polymer extruder that generates beads of molten thermoplastic material and add these beads in sequence so that the parts are manufactured one layer at a time. These layers can be modified and / or flattened into wider beads using devices such as a presser plate or rollers during this additional process. Using these methods, which are sometimes called 3D printing, the parts end up slightly larger than desired. The parts are machined to their final size and shape after cooling and hardening. The resulting parts are generally shells having a specific thickness and a desired approximate size and shape.

[0004] Another type of additive manufacturing can also be referred to as "cut layer" additive manufacturing. In some examples of cut layer additive manufacturing, pieces are cut from a porous material, stacked on top of each other, and adhered together to create a part. In some cases, this part is hollow and consists of individual pieces formed as narrow beads that, when stacked, create a shell or wall around the outer shape of the desired part. In some methods, the shell or wall is constructed from a porous material and an catalytic thermosetting liquid is injected. This liquid is cured to create a rigid composite part reinforced with the porous material.

[0005] However, there may be cases where it is desirable to manufacture parts from non-porous materials such as metals (such as aluminum). Examples of potential uses for such parts include industrial molds and tools used in plastic molding processes such as thermoforming, blow molding, rotational molding, reaction injection molding, etc. Generally, non-porous molds such as aluminum molds may be desirable for these applications when the cost of non-porous (such as aluminum) molds is appropriate and they can be manufactured within an appropriate period.

[0006] Aluminum and other non-porous materials have desirable properties, but one reason they are not used for at least some applications such as molds and tools is that large blocks of material are used for these relatively large parts, and it takes a significant amount of time to remove the excess material (e.g., machining) to create the desired cavity shape of the mold. This is especially true for large and deep parts where it may be necessary to remove more than half of the initial material to achieve the desired shape of the final part.

[0007] One of the features beneficial for continuous production in thermoforming is the ability to control the temperature of the mold surface. In particular, the temperature is controlled to be moderately warm so that the heat-softened thermoplastic sheet can be firmly pressed against the mold surface without the risk of cooling and prematurely hardening. Also, the temperature needs to be low enough so that when the heat-softened thermoplastic sheet comes into full contact with the mold, the sheet is sufficiently cooled to maintain its shape when removed from the mold.

[0008] The temperature at which this process functions properly can vary depending on the formulation of the thermoplastic sheet. Therefore, generally, it is beneficial to appropriately control the temperature of the mold surface. This can be achieved by attaching metal tubes to the underside of the mold surface and circulating temperature-controlled liquid through the tubes. In this method, contact between the metal tubes and the underside of the mold surface is required, but it can be difficult to achieve.

[0009] When manufacturing a mold using cast aluminum, cooling tubes can be incorporated inside the casting itself. This is beneficial, but the process of realizing such a structure is difficult (for example, due to inaccuracies in manufacturing precision). Also, it can be difficult to keep the distance between the casting lines and the mold surface constant.

[0010] In some approaches, channels for temperature-controlled liquid are drilled into the mold body from the outside. However, since such holes are usually drilled in a straight line, the flexibility of the arrangement is limited. Also, the depth to which the holes can be drilled may be limited by the length of the drill bit. In large molds, the length of the drill bit and other tools may be insufficient to form an operable fluid channel.

[0011] It is also difficult to manufacture large aluminum mold castings without forming voids or pores. However, voids and pores can cause defects on the surface of the mold and may distort or leave unacceptable marks on the surface of the molded part.

[0012] Another aspect that is desired for continuous production is the ability to draw and control a vacuum through the mold when making parts with the mold. The amount of vacuum (such as vacuum force) is determined by the maximum size of the holes that can be used without causing distortion such as marks on the surface of the plastic part, and the design constraints are limited. Since it is necessary to prevent the vacuum holes from penetrating the cooling lines, the arrangement of the vacuum holes may also become difficult.

SUMMARY OF THE INVENTION

[0013] Summary Aspects of the present disclosure relate, among other things, to methods and apparatuses for manufacturing parts by additive techniques. Each aspect disclosed herein can include one or more of the features described in relation to any of the other disclosed aspects. An exemplary object of the present disclosure is a method of constructing a mold and / or tool for plastic manufacturing, the mold or tool being formed of a non-porous material such as metal.

[0014] In some aspects of the present disclosure, a method of manufacturing a part (e.g., a mold for plastic processing) includes additive layer manufacturing. The additive layer manufacturing method includes stacking layers (such as metal layers such as aluminum) on top of each other and permanently adhering the layers to each other. Typically, such layers are formed by one or more layer segments, which are stacked and adhered to each other to form relatively narrow walls. These walls can be, for example, about 1.0 to 4.0 inches thick. The additive layer manufacturing method can be used to manufacture relatively large structures using minimal materials.

[0015] A mold is an example of a relatively large structure that can be formed by additive layer manufacturing. An important part of the mold is the surface of the mold that affects the final part. The thickness of the surface of the mold is usually several inches (such as 1.0 inch, 2.0 inches, 3.0 inches, or 4.0 inches) and may be supported by standoffs incorporated into the structure of the mold itself.

[0016] The opening can be machined into the structure of the mold surface. For example, the opening is formed by machining holes or slots in each layer that makes up the mold surface. When the layers of the mold surface are joined together, the holes or slots are aligned, connected, or otherwise made to coincide, creating a flow path through which a temperature-controlled liquid can circulate within the completed mold.

[0017] Holes can be drilled from the bottom of the mold surface structure into the pre-machined closed flow path in the mold surface. The holes drilled from the bottom of the mold surface allow access to one of the flow paths. By drilling holes at both ends of the flow path, a circuit is formed in which a temperature-controlled liquid is introduced at one end of the flow path and removed from the other end, controlling the temperature of the mold surface near the flow path. The ability of the liquid to circulate within the mold surface structure improves heat transfer compared to other methods of mold temperature control.

[0018] Using a corresponding process, a chamber to which a vacuum can be applied can be created within the mold surface itself. This can be done by drilling holes from the bottom of the mold surface structure into the chamber close to the mold surface.

[0019] Thin slots can be machined between the layers of the mold surface. These slots can extend into the vacuum chamber and conduct air from the mold surface towards a vacuum source (e.g., a vacuum pump) during processing. Since the depth of the vacuum slots can be precisely controlled, a path can be created to more rapidly expel the air trapped between the heated and softened thermoplastic sheet and the mold surface. The slots connecting to the vacuum chamber, although narrower than typical vacuum holes, are relatively long, allowing air to be expelled more rapidly without leaving marks on the surface of the molded part. If vacuum holes drilled with a drill were used to achieve the same air evacuation rate, such holes would need to be very large, increasing the risk of leaving marks on the molded surface of the resulting part.

[0020] In one aspect, a component that can be formed by additive manufacturing includes a plurality of layers including a first layer and a second layer, the first layer and the second layer being stacked along a stacking direction, and a working surface being formed on an upper surface of the first layer and an upper surface of the second layer. The component may also include a first through hole formed in the first layer, a second through hole formed in the second layer (the second through hole being at least partially aligned with the first through hole), and a wall extending from the first through hole to the working surface.

[0021] In another aspect, a layer of a mold formed by additive manufacturing can include an upper surface, a lower surface, a front surface, a back surface, and a part of the mold surface on the upper surface. This layer may also include a part of a first coolant flow path penetrating the front surface and the back surface, and a wall formed of a metallic material extending from the first coolant flow path to the mold surface.

[0022] In yet another aspect, an additive manufacturing method can include removing material from a mass of metallic material to form a plurality of layers of a component, forming through holes in the layers, stacking the layers along the stacking direction, and connecting the layers to each other. The layers can form a working surface when stacked. The method may further include aligning the through holes to form a flow path and a wall, the wall extending from the flow path to the working surface.

[0023] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate exemplary aspects of the disclosure and, together with the description, serve to explain the principles of the disclosure.

Brief Description of the Drawings

[0024]

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DETAILED DESCRIPTION OF THE INVENTION

[0025] The present disclosure relates, among other things, to methods and apparatuses for manufacturing multiple components by additive techniques. Specifically, the methods and apparatuses described herein include methods for constructing metal molds and tools for plastic manufacturing, as well as other components. In some aspects, instead of machining a mold from a solid block of material, a mold blank is assembled by stacking components (e.g., layers or layer segments) that are cut from a mass of material such as one or more sheets of material. In some aspects, the material used to form the layers or layer segments may be a porous material such as medium - density fiberboard (MDF), or a solid non - porous material such as aluminum or other metals.

[0026] In aspects of the present disclosure, a laminated mold blank is manufactured. The laminated mold blank may be approximately the same size and shape as the final mold desired to be formed from the mold blank. After assembly, the laminated mold blank is machined precisely to the desired final size and shape. Thereby, parts formed by a conventional additive manufacturing process, i.e., parts having a structure similar to parts constructed in layers, are produced. However, the layers in this exemplary cut layer additive manufacturing process are cut from a sheet of material 12 as shown in FIG. 1. A material removal device such as a CNC router 11 can be configured to perform a high-speed machining or routing process to cut layers or layer segments from the sheet of material 12. In contrast to the layers applied to each other (e.g., via nozzles) during a printing process, the layers and / or layer segments can be assembled. The individual layer segments or layers 14, 15, and 16 can be fixed together in various ways as described below.

[0027] When manufacturing a mold for plastic processing using the disclosed method, the layers 14, 15, and 16 are stacked along the stacking direction 40, permanently adhered to each other, and become layers having relatively narrow walls (e.g., a thickness of about 1.0 to about 4.0 inches). As shown in FIG. 2, a relatively large structure such as part 17 can be manufactured with a minimum amount of material by stacking layers in the stacking direction 40. The layers 14, 15, 16, and thus the part 17 can be formed of a metallic material such as aluminum.

[0028] FIG. 3 shows an exemplary part 17 in the form of a mold, which includes a support structure in the form of a rectangular box 18 having an upper surface 19 having the shape of an item (e.g., from a plastic material) to be manufactured with the mold. The box 18 may be a solid block of solid aluminum or other material in at least some parts or processes. However, a cavity may be formed at the bottom of the box 18 as needed. A mold of the type shown in FIG. 3 as an example of part 17 can be used in one or more plastic part forming processes such as thermoforming, blow molding, rotational molding, reaction injection molding.

[0029] Regardless of the process used to form the item with the mold 17, the useful part of the mold 17 is the mold surface 19, and the mold surface 19 defines the size and shape of the item to be manufactured. The remaining part of the mold 17 may include most of the material of the mold 17 (e.g., more than 50% measured by weight or volume) and is formed by the mold structure 20. The mold structure 20 supports the mold surface 19 and can be used to attach the mold surface 19 to a suitable molding machine.

[0030] Referring to FIG. 4, as described above, the important structure of the mold 17 formed by the cutter layer additive manufacturing method is the mold surface 19. The mold surface 19 is an example of the working surface on the upper surface of the part 17 and is the surface used to manufacture parts in the example of the mold. Different types of parts 17 can have a working surface that performs a function and / or a decorative working surface (e.g., structural members, connectors, patterned surfaces, aerodynamic shapes, etc.).

[0031] The mold surface 19 has a thickness of about 1.0 to about 4.0 inches and is supported by one or more supports such as the box 18 or the standoff 29. The standoff 29 may be formed as a structure integrated into the structure of the mold 17 itself. Alternatively, the standoff 29 may be a separate support structure fixed to one or more layers of the part 17 in a way that does not interfere with the mold surface 19.

[0032] As shown in FIG. 4, the standoffs 29 are formed as the first and last layers (e.g., at the ends of the mold 17). These layers may be formed by the cutter layer additive manufacturing process described above, in which the machine 11 (FIG. 1) forms the layers by removing material from the sheet. When assembled, these layers extend away from the mold surface 19 (e.g., downward) respectively to create the support for the mold 17.

[0033] In the example shown in FIG. 4, each standoff 29 is formed from a single layer of the mold 17, and the standoff forms one of two mounting legs at the opposite end of the mold 17. If desired for a particular part 17, the standoff 29 can instead be formed by a plurality of adjacent layers, resulting in a thicker standoff 29. Further, although two standoffs 29 are shown, a single standoff 29 (e.g., along the central portion of the mold 17 or the entire length of the mold 17, as described later) may be used, or there may be three or more standoffs 29.

[0034] Referring to FIGS. 5 and 6, the standoff can be formed in the shape of a rectangular box 18. FIG. 5 is a view showing the outside of the mold in which the box 18 is formed at the bottom of the mold. The mold shown in FIG. 5 is similar to the above-described mold formed by cutter layer manufacturing, the box 18 is rectangular, the mold surface 19 forms an upper surface having the shape of the item to be manufactured, and the standoff 29 is formed at the opposite end of the mold, on the side panel 31 and the bottom panel (not shown).

[0035] FIG. 6 is a bottom view showing the bottom end of the box 18 and the inside of the box 18 when the box 18 is hollow. As shown in FIG. 6, the box 18 can include the perimeter formed by the standoff 29 and the side panel 31. This perimeter is shown as having a rectangular shape, but other shapes (e.g., more complex geometric shapes, circular, etc.) are also possible.

[0036] One or more internal reinforcing supports 30 can be fixed within the box 18 to provide additional support force and rigidity. For example, one or more internal supports 30 can extend in a direction parallel to the standoff 29 or in a direction parallel to the side panel 31. Additionally, or alternatively, the support 30 may extend at an angle oblique to the standoff 29 and the side panel 31. Each support 30 may extend substantially parallel to the layer (two examples of this direction are shown in FIG. 6) or may extend perpendicular to one or more layers (one example of this direction is shown in FIG. 6). The support 30 may be formed at the bottom of the mold 17, but the support 30 may also be disposed between the lower and upper ends of the mold 17. The box 18 may include a plurality of supports 30, including supports 30 at different heights. A single support 30 may be disposed at a single height, but alternatively the support 30 may be angled vertically and span multiple heights, connecting opposite ends of a single layer or connecting different layers at different vertical heights.

[0037] FIG. 7 shows one example of the layer 14 also shown in FIGS. 1, 2, 4, and 5. The layer 14 formed by the cutter layer additive manufacturing method by the machine 11 can include structures for forming a cooling and / or heating system within the part when the layer 14 is assembled with additional layers. These structures can be useful in a mold as described above.

[0038] As shown in FIG. 7, the upper side of the layer 14 forms at least a part of the surface 19 and includes holes 21 and slots 22 on the front and rear surfaces. The lower side of the layer 14 is on the opposite side of the mold surface 19 at the bottom of FIG. 7.

[0039] The openings can be made in at least a part of the layer (e.g., layer 14) that forms a part of the mold surface 19. If necessary, the openings can also be formed in layers that are not part of the mold surface 19. These openings can be created by machining through holes 21 and slots 22 (which may be rectangular or other shapes and may be considered through holes).

[0040] The hole 21, the slot 22, or both are machined into each layer that forms part of the mold surface 19 such that when the layers are joined, the holes 21 are at least partially aligned or fully aligned and overlap with the holes 21 of one or more other layers. Similarly, the slots 22 can be at least partially aligned or fully aligned and overlap with the slots 22 of one or more other layers. Thereby, the holes 21 can create flow paths through which a temperature-controlled liquid (e.g., coolant) can circulate. The aligned slots 22 can facilitate a vacuum flow away from the mold surface 19 through the slots 22. In some embodiments, the holes 21 and the slots 22 are drilled through the bottom of the mold surface 19. When aligned, the holes 21 and the slots 22 can form respective flow paths separated from each other for fluid circulation and vacuum application, respectively.

[0041] Figure 7 shows a circular hole 21 and a rectangular slot 22, but other shapes are possible. For example, the hole 21 may be formed as a rectangular slot and the slot 22 may be formed as a circular hole. The hole 21 and the slot 22 may be formed by removing material with the machine 11 as part of a process of removing material from the sheet 12 of material to form layers and / or layer segments. For example, the holes 21 and the slots 22 may be formed in the respective appropriate layers before the layers 14, 15, and 16 are completely separated from the sheet 12 of material.

[0042] Figure 8 is a wireframe view of approximately half of the component 17 in which a plurality of layers are assembled to form the mold surface 19. In Figure 8, each layer extends generally in a vertical direction and the individual layers are stacked generally in a horizontal direction.

[0043] Figure 8 shows seven coolant channels 24, with each layer containing a respective part of each of the seven channels 24. Each channel 24 starts at an inlet 25 and ends at an outlet 26. Between the inlet 25 and the outlet 26, at least one channel may form a horizontally extending portion (including higher or lower regions in height). Access to each channel 24 is provided via a hole opened from the bottom of the part, and the hole forms a part of the channel 24 that extends orthogonally to the stacking direction 40 (Figure 2). In particular, all inlets 25 and / or all outlets 26 may be drilled through the bottom surface of the mold on the opposite side of the mold surface 19 to form downward openings. Downward openings can be formed by the inlets 25 and / or the outlets 26. However, one or more inlets 25 and / or outlets 26 may be formed on the side surface of the layer as required.

[0044] A temperature-controlled liquid (e.g., coolant. Here, "coolant" is used to refer to a fluid for cooling, heating, or both cooling and heating) can be introduced into each channel 24 via a bore or hole (inlet 25) formed at the end of the channel 24. The temperature-controlled fluid can be removed from each channel via an outlet 26 at the opposite end of the channel 24. The circulation of the temperature-controlled liquid can facilitate the control of the temperature of the mold surface 19 adjacent to the channel 24.

[0045] The channels 24 may be formed to follow the profile of the mold surface 19. As shown in Figure 8, each channel 24 may extend in a direction substantially aligned (coincident) with the direction in which the individual layers of the part 17 are stacked and assembled. The height of one or more channels 24 may increase or decrease according to the profile defined by the mold surface 19. For example, some of the channels 24 in Figure 8 are shown to increase in height before decreasing in height in the direction extending from the inlet 25 towards the outlet 26.

[0046] The flow paths 24 may be uniformly distributed (e.g., arranged at intervals), or may be concentrated. The distance between each flow path 24 may increase or decrease in different parts of the component 17. For example, the flow paths 24 are closer to each other in the regions of the mold surface 19 that are expected to receive more heat (e.g., the central part of the mold surface 19, or the part of the mold surface 19 designed to receive more material for molding), farther apart in the parts of the mold surface 19 that receive less heat, or farther apart in the regions that do not include a part of the mold surface 19.

[0047] The paths of each flow path 24 as shown in FIG. 8 may be difficult or impossible to form in a mold made from a solid material block. For example, the flow paths 24 may extend in a plurality of different directions within the component 17. In the illustrated paths, each inlet 25 extends upward from the bottom surface of the component 17, each outlet 26 extends upward from the bottom surface of the component 17, and the portions of each flow path 24 between the inlet 25 and the outlet 26 follow a path generally perpendicular to the inlet 25 and the outlet 26, and there are also regions extending upward or downward in these portions. Therefore, using the cutter layer stacking technology may facilitate the formation of the flow paths 24 for circulating the liquid within the structure of the mold surface 19 itself. Forming the flow paths 24 at this position may improve heat transfer and control compared to other methods of controlling the mold temperature.

[0048] As shown in the wireframe diagram of the component 17 in FIG. 9 (about half of the component 17 is shown), a chamber 27 to which a vacuum can be applied can be created using the cutter layer stacking manufacturing process. The chamber 27 can be formed within the mold surface 19. Each chamber 27 has a closed-loop path, and about half of this path is shown in FIG. 9. The closed-loop path of the chamber 27 is connected to a hole in the bottom surface of the component 17 to form a vacuum connection portion 32, and one or more openings are formed, for example, by slots. Through the openings, each chamber 27 can apply a vacuum to the upper surface of the component 17 as described below.

[0049] Each connection part 32 can penetrate the outer surface of the component 17 and connect the chamber 27 to one or more vacuum pumps. This connection part can be formed by opening holes (not shown) in each chamber 27 from the bottom of the structure of the mold surface 19.

[0050] FIG. 10 is an enlarged view of a portion 10 (FIG. 9) of the component 17, and the portion 10 includes a pair of abutting layers 34 and 35. The portion 10 of the component 17 represents an example of a configuration in which the chamber 27 is fluidly connected to the mold surface 19. As shown in FIG. 10, the vacuum passage or slot 28 can be machined at the interface between the layers 34 and 35 by removing material from the end faces of the layer 34, the layer 35, or both the layers 34 and 35. Therefore, the slot 28 may be formed as a recess in the layer 34 and / or the layer 35. The slot 28 has a depth 33, a length 37, and a width 36, and the length 37 is greater than the depth 33 and greater than the width 36. The slot 28 can extend downward from the mold surface 19 to the vacuum chamber 27 in order to discharge air from the mold surface 19 during the processing of the plastic product manufactured by the component 17. Therefore, each slot 28 may form a narrow opening with a width 36 and a length 37 in the mold surface 19.

[0051] When using the cut layer additive manufacturing method, the depth 33 of the vacuum slot 28 can be accurately controlled. Therefore, there is a possibility of creating a path for discharging the air trapped between the heated and softened thermoplastic sheet and the mold surface 19 more quickly than other processes.

[0052] The slot 28 may be thin when measured by the width 36 (for example, in a direction parallel to the direction 40 in which the layers 34 and 35 are laminated as shown in FIG. 2) compared to the diameter of the vacuum holes formed by other processes. Furthermore, the slot 28 may be relatively long when measured along the length 37, whereby air can be discharged more quickly than other methods and no traces will remain on the surface of the molded product. For example, in a conventional process of drilling vacuum holes at a similar air discharge rate, traces may remain on the molded surface of the resulting product.

[0053] If necessary, additional processing can be performed on the part 17 to further prevent traces from remaining on the molded product, particularly at the parting lines formed between pairs of adjacent layers. The additional processing may include coating the surface of the mold 17 with a wear-resistant material. This coating can be applied, for example, to the mold surface 19. The coating can be a plasma-sprayed metal, ceramic, or electroplated material (e.g., chromium applied by chrome plating). The coating process can advantageously create a more wear-resistant working surface, reducing or eliminating the traces formed on the part by the seams between the layers. Also, using a coating on the mold 17 can prevent wear caused by repeatedly molding items on a mold 17 made of aluminum or other non-porous materials. This can potentially improve the lifespan of the mold 17, particularly the mold 17 used for tooling applications.

[0054] From the foregoing detailed description, it is apparent that numerous changes, adaptations, and modifications can be made to the present disclosure by those of ordinary skill in the art to which the foregoing disclosure pertains. However, it is intended that all such changes that do not depart from the spirit of the present disclosure be considered within the scope of the present disclosure as limited by the appended claims.

Description of Reference Numerals

[0055] 11 Machine (material removal device) 14, 15, 16 Layers 17 Part (mold) 19 Mold Surface (working surface) 21 Through Hole 24 Channel (coolant flow path) 27 Chamber (vacuum chamber) 28 Slot 30 Internal Support Portion 34 Layer 35 Layer 40 Laminating Direction

Claims

1. A component formed by an additive manufacturing method, comprising a plurality of layers including a first layer and a second layer, the first layer and the second layer being stacked along the stacking direction, the plurality of layers, a working surface formed on the upper surface of the first layer and the upper surface of the second layer, a first through hole formed in the first layer, a second through hole formed in the second layer, the second through hole being at least partially aligned with the first through hole, the second through hole, and a wall extending from the first through hole to the working surface.

2. a third through hole formed in the first layer, a fourth through hole formed in the second layer, the third through hole being at least partially aligned with the fourth through hole, the fourth through hole, The component according to claim 1, further comprising.

3. The first through hole and the second through hole each have a first shape, The third through hole and the fourth through hole each have a second shape different from the first shape. The component according to claim 2.

4. The working surface further includes an opening, The component according to claim 2, wherein the opening is connected to the third through hole and the fourth through hole.

5. The component according to claim 4, wherein the opening is formed in a shape of the slot having a length longer than the width of the slot.

6. The first through hole and the second through hole form a portion extending in the horizontal direction of the coolant flow path, and the coolant flow path has a downward opening. The component according to claim 1.

7. The coolant flow path is a first coolant flow path, the component includes a second coolant flow path, and the second coolant flow path extends through the first layer and the second layer. The component according to claim 6.

8. The component is a mold, and the mold includes a support structure. The component according to claim 1.

9. The support structure is hollow and includes an internal support portion. The component according to claim 8.

10. Upper surface, Lower surface, Front surface, Rear surface, A part of the mold surface on the upper surface, A part of the first coolant flow path extending through the front surface and the rear surface, and A wall formed of a metal material extending from the first coolant flow path to the mold surface A layer of the mold comprising.

11. The layer according to claim 10, further comprising a part of a second coolant flow path passing through the front surface and the rear surface.

12. The layer according to claim 10, further comprising a part of a vacuum chamber extending through the front surface and the rear surface.

13. further comprising a recess formed by the material removed from the front surface or the rear surface; The layer according to claim 12, wherein the recess extends from the mold surface to the vacuum chamber. **Claim 14** The layer according to claim 10, wherein the mold surface extends from the front surface to the rear surface of the layer. **Claim 15** A layer manufacturing method, comprising: removing material from a mass of a metallic material to form a plurality of layers of a component; forming a through hole in the layer; stacking the layers along a stacking direction and connecting the layers that form a working surface when stacked together; aligning the through holes to form a flow path and a wall, the wall extending from the flow path to the working surface, forming the flow path and the wall A layer manufacturing method having the above steps. **Claim 16** The layer manufacturing method according to claim 15, wherein the flow path is configured to supply a coolant inside each of the layers when formed. **Claim 17** further comprising forming a third layer, The layer manufacturing method according to claim 16, wherein the third layer includes a part of the flow path extending in a direction orthogonal to the stacking direction. **Claim 18** further comprising forming a slot in the layer, The layer manufacturing method according to claim 15, wherein the slot forms a part of the vacuum chamber when the through holes are aligned. **Claim 19** The layer manufacturing method according to claim 18, wherein the through holes and the slots are formed by removing the metallic material from the layer by a material removal device that removes the metallic material to form the layer. **Claim 20** The layer manufacturing method according to claim 19, further comprising removing material from a surface of one of the layers to form a vacuum passage extending from the working surface to the vacuum chamber.

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