Sand casting hybrid tooling pattern insert within a recess of a plate formed via additive manufacturing

Abstract

A method of manufacturing a sand casting hybrid tooling pattern plate used to form a mold from foundry sand includes providing a base plate having a first surface and a second surface opposite the first surface, forming a recess in the first surface of the base plate, forming, via additive manufacturing, a pattern member, positioning the pattern member within the recess such that a first portion of the pattern member is positioned within the recess and a second portion of the pattern member extends from the first surface of the base plate, and coupling the pattern member to the base plate.

Description

Attorney Docket No. 208273 -0012- WOO 1SAND CASTING HYBRID TOOLING PATTERN PLATE AND METHOD OF MANUFACTURING THE SAME VIA COUPLING AN INSERT, FORMED VIA ADDITIVE MANUFACTING, WITHIN A RECESS OF A PLATECROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 701,660, filed on October 1, 2024, the entire contents of which are incorporated herein.FIELD

[0002] Embodiments relate to a sand casting hybrid tooling pattern plate and a method of manufacturing the same.BACKGROUND OF THE DISCLOSURE

[0003] To produce parts in metals via a sand casting method, it is necessary to compress prepared foundry sand with tooling to form suitable mold cavities into which metal may be poured.

[0004] This requires tooling representative of the desired part which is the ‘master’ or ‘pattern’ from which the mold is being made. To produce both sides of a mold at once, this pattern usually takes the form of a plate with the part geometries mounted on both sides. This plate is traditionally either cut from a monolithic block of material, assembled from multiple machined components, or built up out of carved and hand-worked pieces of wood, tooling board, or other suitable materials worked and blended together to produce a suitable pattern against which to compress foundry sand to form molds.

[0005] The production of pattern plates by traditional methods is both time and labor intensive, and in machining approaches requires substantial material removal to achieve desired part forms.

[0006] For multi-part patterns, assembly usually requires extensive use of fasteners to combine the components together, which introduces a number of knock-on effects and concerns which require additional labor and cost to resolve.Attorney Docket No. 208273 -0012- WOO 1SUMMARY

[0007] In some aspects, the techniques described herein relate to a method of manufacturing a sand casting hybrid tooling pattern plate , the tooling pattern plate used to form a mold from foundry sand, the method including: providing a base plate having a first surface and a second surface opposite the first surface; forming a recess in the first surface of the base plate; forming, via additive manufacturing, a pattern member; positioning the pattern member within the recess such that a first portion of the pattern member is positioned within the recess and a second portion of the pattern member extends from the first surface of the base plate; and coupling the pattern member to the base plate.

[0008] In some aspects, the techniques described herein relate to a method, wherein forming the recess in the first surface of the base plate includes forming the recess in the first surface via machining.

[0009] In some aspects, the techniques described herein relate to a method, wherein the base plate includes a metal.

[0010] In some aspects, the techniques described herein relate to a method, wherein the metal includes aluminum, a magnesium alloy, cast iron, or steel.

[0011] In some aspects, the techniques described herein relate to a method, wherein forming, via additive manufacturing, the pattern member includes forming, via additive manufacturing, the pattern member from a photopolymer.

[0012] In some aspects, the techniques described herein relate to a method, wherein the photopolymer has an elongation at break of at least 3%.

[0013] In some aspects, the techniques described herein relate to a method, wherein the photopolymer has a heat deflection temperature at 0.455 MPa of at least 100 °F.

[0014] In some aspects, the techniques described herein relate to a method, wherein the photopolymer has a hardness of about 85D.Attorney Docket No. 208273 -0012- WOO 1

[0015] In some aspects, the techniques described herein relate to a method, wherein coupling the pattern member to the base plate includes coupling the pattern member within the recess via an adhesive.

[0016] In some aspects, the techniques described herein relate to a method, wherein the recess is a first recess and the pattern member is a first pattern member, and further including: forming a second recess in the second surface of the base plate; forming, via additive manufacturing, a second pattern member; and positioning the second pattern member within the second recess such that a first portion of the second pattern member is positioned within the second recess and a second portion of the second pattern member extends from the second surface of the base plate.

[0017] In some aspects, the techniques described herein relate to a method, wherein coupling the first pattern member within the first recess includes coupling the pattern member within the first recess via an adhesive and further including coupling the second pattern member to the base plate by coupling the second pattern member within the second recess via the adhesive.

[0018] In some aspects, the techniques described herein relate to a method, wherein forming the first recess and the second recess includes creating an aperture that extends through the base plate between the first recess and the second recess, wherein forming, via additive manufacturing, the first pattern member and the second pattern member includes forming, via additive manufacturing, the first pattern member with a first interface and the second pattern member with a second interface that is complementary to the first interface, and wherein positioning the first pattern member within the first recess includes positioning the first interface through the aperture and positioning the second pattern member within the second recess includes engaging the second interface with the first interface of the first pattern member.

[0019] In some aspects, the techniques described herein relate to a method, wherein forming the first recess and the second recess includes creating an aperture that extends through the base plate between the first recess and the second recess, and further including coupling the first pattern member to the second pattern member through the aperture in the base plate.Attorney Docket No. 208273 -0012- WOO 1

[0020] In some aspects, the techniques described herein relate to a method, wherein the pattern member is a first pattern member, and further including forming, via additive manufacturing, a second pattern member; and positioning the second pattern member within the recess such that a first portion of the second pattern member is positioned within the recess and a second portion of the second pattern member extends from the first surface of the base plate.

[0021] In some aspects, the techniques described herein relate to a method, wherein the second pattern member is coupled between the first pattern member and the base plate.

[0022] In some aspects, the techniques described herein relate to a method, further including applying a ceramic coating on at least a portion of the base plate, at least a portion of the pattern member, or both.

[0023] In some aspects, the techniques described herein relate to a method, wherein the ceramic coating is derived from a polymer system selected from the group consisting of a polyurethane, an epoxy, an acrylate, a methyl or phenyl modified silicone, and any of the foregoing further including an engineering ceramic.

[0024] In some aspects, the techniques described herein relate to a method, wherein coupling the pattern member to the base plate includes coupling the pattern member to the base plate without fasteners.

[0025] In some aspects, the techniques described herein relate to a sand casting hybrid tooling pattern plate , the tooling pattern plate used to form a mold from foundry sand, the tooling pattern plate including: a metal base plate including a first surface, a second surface opposite the first surface, and a recess in the first surface; and a photopolymer pattern member positioned within the recess, a portion of the photopolymer pattern member extending from the first surface.

[0026] In some aspects, the techniques described herein relate to a sand casting hybrid tooling pattern plate, wherein the photopolymer has an elongation at break of at least 3%.Attorney Docket No. 208273 -0012- WOO 1

[0027] In some aspects, the techniques described herein relate to a sand casting hybrid tooling pattern plate, wherein the photopolymer has a heat deflection temperature at 0.455MPa of at least 100 °F.

[0028] In some aspects, the techniques described herein relate to a sand casting hybrid tooling pattern plate, wherein the photopolymer has a hardness of about 85D.

[0029] In some aspects, the techniques described herein relate to a sand casting hybrid tooling pattern plate, wherein the metal includes aluminum, a magnesium alloy, cast iron, or steel.

[0030] In some aspects, the techniques described herein relate to a sand casting hybrid tooling pattern plate, further including adhesive between the photopolymer pattern member and a surface of the recess.

[0031] In some aspects, the techniques described herein relate to a sand casting hybrid tooling pattern plate, wherein the recess is a first recess and the photopolymer pattern member is a first photopolymer pattern member, wherein the metal base plate further includes a second recess in the second surface, and further including a second photopolymer pattern member positioned within the second recess, a portion of the second photopolymer pattern member extending from the second surface.

[0032] In some aspects, the techniques described herein relate to a sand casting hybrid tooling pattern plate, further including an adhesive between the first photopolymer pattern member and a surface of the first recess and an adhesive between the second photopolymer pattern member and a surface of the second recess.

[0033] In some aspects, the techniques described herein relate to a sand casting hybrid tooling pattern plate, further including an aperture extending through the metal base plate from the first recess to the second recess, and wherein the first pattern member is coupled to the second pattern member through the aperture.

[0034] In some aspects, the techniques described herein relate to a sand casting hybrid tooling pattern plate, wherein the photopolymer pattern member is a first photopolymer patternAttorney Docket No. 208273 -0012- WOO 1 member, and further including a second photopolymer pattern member positioned within the recess, a portion of the second photopolymer pattern member extending from the first surface.

[0035] In some aspects, the techniques described herein relate to a sand casting hybrid tooling pattern plate, further including a ceramic coating applied to at least a portion of the base plate, at least a portion of the pattern member, or both.

[0036] In some aspects, the techniques described herein relate to a sand casting hybrid tooling pattern plate, wherein the ceramic coating is derived from a polymer system selected from the group consisting of a polyurethane, an epoxy, an acrylate, a methyl or phenyl modified silicone, and any of the foregoing further including an engineering ceramic.

[0037] In some aspects, the techniques described herein relate to a sand casting hybrid tooling pattern plate, wherein the photopolymer pattern member is coupled to the metal base plate without fasteners.BRIEF DESCRIPTION OF THE DRAWINGS

[0038] FIG. l is a method for manufacturing a sand casting hybrid tooling pattern plate.

[0039] FIG. 2 is a perspective view of a base plate of the sand casting hybrid tooling pattern plate formed via the method of FIG. 1.

[0040] FIG. 3 is a cross-sectional view of the sand casting hybrid tooling pattern plate formed via the method of FIG. 1 and including a first pattern member and a second pattern member coupled to the base plate of FIG. 2.

[0041] FIG. 4 is another cross-sectional view of the sand casting hybrid tooling pattern plate formed via the method of FIG. 1.

[0042] FIG. 5 is a perspective view of a base plate and pattern member of the sand casting hybrid tooling pattern plate according to a further embodiment.DETAILED DESCRIPTIONAttorney Docket No. 208273 -0012- WOO 1

[0043] Before any embodiments are explained in detail, it is to be understood that the application is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. Other embodiments, than those described below, are capable of being practiced or of being carried out in various ways.

[0044] FIG. 1 illustrates a method 100 of manufacturing a sand casting hybrid tooling pattern plate (e.g., tooling pattern plate). The resulting tooling pattern plate 200, once manufactured, is used to form a mold from foundry sand. The method includes, at step 104, providing a base plate 204 having a first surface 204a and a second surface 204b opposite the first surface 204a. The method further includes, at step 108, forming a recess 208a, 208b into the base plate 204. The method further includes, at step 112, forming, via additive manufacturing, a pattern member 300a, 300b, 300c of a pattern. Collectively, the pattern members 300a, 300b, 300c make up a pattern. The method further includes, at step 116, positioning the pattern member 300a, 300b, 300c within the recess 208a, 208b. The method further includes, at step 120, coupling the pattern member 300a, 300b, 300c to the base plate 204. The pattern member 300a, 300b, 300c may be coupled to the base plate 204 within the recesses 208a, 208b. Preferably, the pattern member 300a, 300b, 300c is coupled to the base plate 204 within the recess 208a, 208b with minimal or no fasteners.

[0045] With respect to step 104, the base plate 204 is preferably formed from or includes a metal. Accordingly, the method 100 may further include forming the base plate 204 from a metallic material (e.g., a flat plate stock). For example, the base plate 204 may be formed via casting, forging, extruding, rolling, or machining the base plate 204 from a metallic material, such as aluminum, magnesium alloy (Dowmetal), cast iron, or steel, although any suitable metal may be used.

[0046] In other embodiments, with respect to step 104, the base plate 204 may be formed from a non-metallic material (e.g., wood or polymer) using any suitable method. Accordingly, the method 100 may further include forming the base plate 204 from a nonmetallic material. In one example, the base plate 204 may be formed, via any suitable process (such as machining), from wood. In another example, the base plate 204 may be formed via additive manufacturingAttorney Docket No. 208273 -0012- WOO 1 using a polymer material. Accordingly, the base plate 204 can include a polymer. Any suitable additive manufacturing technique may be used to create the base plate 204. Additionally, the base plate 204 may be formed in any suitable way. For example, the base plate 204 can be made via filament or pellet-fed extrusion deposition, sheet lamination, directed-energy deposition, selective laser sintering, continuous fiber placement, material jetting, casting, injection molding, compression molding, thermoforming, or machined from stock, to name some potential techniques.

[0047] If used, the polymer used for the base plate 204 is not generally limited, and can be any polymer that has the requisite mechanical properties to function as a base plate 204 in a sand casting tooling pattern plate. For example, match plates need sufficient flexural and compressive strength to tolerate up to ~ 150psi transient loads, thermal operating range to maintain strength in hot foundry conditions and processing steps up to 150°F, abrasion resistance to foundry sand with a minimum ASTM-D3363 rating of 8H, and stiffness to resist deflection under uneven sand packing. Example polymers which can be used include, but are not limited to, nylons, PEI, PPA, PEEK, PEKK, PC, ASA, ABS, and UHMW.

[0048] The polymer can be used neat or compounded with an additive such as reinforcing spherical, rough, or fibrous additives. Compounded polymers may also be referred to as polymer composites. In embodiments where the polymer is a polymer composite, the polymer can include at least one other material that can improve mechanical properties of the polymer. An example material includes, but is not limited to, a fiber (e.g., a reinforcing fiber). The fiber can be suspended or spread out in a polymer matrix. Example fibers include, but are not limited to, glass, carbon, basalt, aramid, and combinations thereof. In some embodiments, the polymer includes an additive, such as but not limited to, chopped carbon fibers.

[0049] As explained above, the base plate 204 may be formed from either metallic or nonmetallic materials. With respect to step 108, the recess 208a, 208b may be formed in any suitable way depending on the material of the base plate 204. For example, if the base plate 204 includes a metallic material, the recess 208a, 208b may be formed via machining or forging. The term “machining” as used herein is a subtractive manufacturing process in which a material is removed from the base plate 204. The material may be removed using any suitable means andAttorney Docket No. 208273 -0012- WOO 1 may include a combination of means. Alternatively, the recess 208a, 208b may be formed at the same time as the base plate 204. The recesses 208a, 208b may be formed using any suitable method. In one example, if the base plate 204 is formed using casting with a non-metallic material (e.g., polymer) or metallic material (e.g., a material including metal), the recess 208a, 208b may also be formed as the base plate 204 is formed. For example, if the base plate 204 is formed using additive manufacturing with a non-metallic material (e.g., polymer material), the recess 208a, 208b may also be formed as the base plate 204 is formed.

[0050] Further with respect to step 108, in some embodiments, the method includes forming one or more recesses 208a, 208b into the first surface 204a, the second surface 204b, or both. In some embodiments, the method may include forming a first recess 208a into the first surface 204a and a second recess 208b into the second surface 204b. Such an exemplary base plate 204 is shown in FIGS. 2-4. The first recess 208a is defined by a first recessed surface 220 and a first wall 224 extending between the first recessed surface 220 and the first surface 204a of the base plate 204. A first shape of the first recess 208a is defined by the first recessed surface 220 and the first wall 224. The second recess 208b is defined by a second recessed surface 230 and a second wall 234 extending between the second recessed surface 230 and the second surface 204b of the base plate 204. A second shape of the second recess 208b is defined by the second recessed surface 230 and the second wall 234. In the illustrated embodiment, the recessed surface 220, 230 the first wall 224, 234 of the respective recesses 208a, 208b are illustrated as being generally perpendicular to one another. That is, the “comer” of each of the recesses 208a, 208b creates a generally 90 degree angle. In other embodiments, a surface between the recessed surface 220, 230 and the first wall 224, 234 may be arcuate or rounded. That is, the “corner” of each of the recesses 208a, 208b may have an arcuate surface.

[0051] In the illustrated embodiment, the first recess 208a and the second recess 208b have different shapes, but in other embodiments, the first recess 208a and the second recess 208b may have the same shape. In other embodiments, the first recess 208a may have any suitable size and shape and the second recess 208b may have any suitable size and shape. In the embodiment of FIGS. 2-4, the first recess 208a has a different shape than the second recess 208b, yet the first recess 208a at least partially overlaps the second recess 208b. In other embodiments, the first recess 208a may be positioned at any location relative to the second recess 208b. In other words,Attorney Docket No. 208273 -0012- WOO 1 the first and second recesses 208a, 208b may overlap entirely, partially overlap, or not overlap at all. Additionally, although only a single recess 208a, 208b is included in each of the first surface 204a and the second surface 204b, the base plate 204 may have additional recesses in each of the first and second surfaces 204a, 204b. In still other embodiments, there may be one or more recesses in one of the surfaces 204a, 204b, while there are no recesses in the other of the surfaces 204a, 204b. In such case, only one of the surfaces 204a, 204b may include a pattern member 300a, 300b, 300c.

[0052] Additionally, the recesses 208a, 208b may be formed (via machining or casting or another suitable process) such that the base plate 204 includes an aperture 240 extending through the base plate 204 between the first recess 208a and the second recess 208b. In the illustrated embodiment, the recesses 208a, 208b may be formed such that the base plate 204 includes two apertures 240 extending therethrough between the first recess 208a and the second recess 208b. In other embodiments, the apertures 240 may be omitted, there may be a single aperture 240, or there may be more than two apertures 240. Additionally, in the illustrated embodiment, the recesses 208a, 208b are formed such that a groove 250 in the recessed surface 220 surrounds each of the apertures 240. The grooves 250 circumscribe the corresponding aperture 240 in the illustrated embodiment. The grooves 250 may be omitted or have other shapes. In other embodiments, the groove 250 may be replaced by a rib.

[0053] With respect to step 1 12, though “additive manufacturing” is an industry standard term (ASTM F2792), additive manufacturing encompasses various manufacturing and prototyping techniques known under a variety of names, including freeform fabrication, 3D printing, rapid prototyping / tooling, and the like. Additive manufacturing techniques are capable of fabricating complex components from a wide variety of materials. Generally, a freestanding object can be fabricated from a computer aided design (CAD) model. A particular type of additive manufacturing process uses light to solidify a photopolymer, creating a solid three- dimensional object.

[0054] With respect to step 112, in some embodiments, the pattern members 300a, 300b, 300c may be formed from a photopolymer / photopolymer system via large format vat photopolymerization. In other embodiments, the pattern members 300a, 300b, 300c may beAttorney Docket No. 208273 -0012- WOO 1 formed from a polymer via other suitable additive manufacturing techniques. As used herein, a photopolymer system is a combination of monomers, oligomers, and suitable catalysts (photoinitiators) that can be cured into final polymer chains (e.g., transformed from a liquid state to a solid state) in the presence of an activating wavelength band of light that stimulates the photoinitiator in the polymer system, such as one or more of ultraviolet light, visible-light, or infrared-light. Photopolymers can be commercially purchased and can be derived from monofunctional and / or multifunctional monomers having different functional groups, which can comprise polymer systems such as, but not limited to, acrylates, methylacrylates, urethanes, and epoxies.

[0055] The photopolymer can have advantageous properties that make it useful in the disclosed sand casting hybrid tooling pattern plates and methods thereof. For example, the photopolymer can have an elongation at break of at least 3%, at least 4%, at least 5%, at least 6%, at least 7%, at least 8%, at least 9%, at least 10%, at least 15 %, at least 20%, at least 25%, or at least 30%. In some embodiments, the photopolymer has an elongation at break of at most 35%, at most 30%, at most 25%, at most 20%, at most 15%, at most 10%, at most 9%, at most 8%, at most 7%, at most 6%, or at most 5%. In some embodiments, the photopolymer has an elongation at break of about 3% to about 35%, such as about 3% to about 30%, about 3% to about 20%, about 3% to about 10%, about 5% to about 20%, about 5% to about 30%, or about 10% to about 30%. The elongation at break can be measured via ASTM D-638-05.

[0056] The photopolymer can have a heat deflection temperature (HDT) at 0.455 MPa of at least 100 °F, at least 105 °F, at least 110 °F, at least 115 °F, at least 120 °F, at least 130 °F, at least 140 °F, or at least 150 °F. In some embodiments, the photopolymer has an HDT at 0.455 MPa of at most 200 °F, at most 190 °F, at most 180 °F, at most 170 °F, at most 160 °F, or at most 150 °F. In some embodiments, the photopolymer has an HDT at 0.455 MPa of about 100 °F to about 200 °F, such as about 100 °F to about 150 °F, about 100 °F to about 125 °F, about 110 °F to about 180 °F, about 120 °F to about 160 °F, about 125 °F to about 200 °F, or about 150 °F to about 200 °F. The HDT can be measured via ASTM-D-648.Attorney Docket No. 208273 -0012- WOO 1

[0057] The photopolymer can also have a hardness of about 60D to about 100D, such as about 65D to about 95D, about 70D to about 90D, about 75D to about 95D, about 80D to about 90D, or about 85D to about 87D.

[0058] Further with respect to step 112, the method may further include forming, via additive manufacturing, at least one pattern member 300a, 300b corresponding to each recess 208a, 208b. For example, in the illustrated embodiment, a first pattern member 300a and a second pattern member 300b are each formed using additive manufacturing. In the illustrated embodiment, the pattern members 300a, 300b are formed, via additive manufacturing, from a photopolymer, as noted above.

[0059] In the illustrated embodiment, each of the first pattern member 300a and second pattern member 300b includes a first portion 340a, 340b and a second portion 344a, 344b. The first portion 340a, 340b is sized and shaped to be received within at least a portion of the respective recess 208a, 208b. In some embodiments, one or a combination of surfaces of the insert 300a, 300b may include a geometric pattern (e.g., a honeycomb pattern, not shown). The geometric pattern is produced in the additive manufacturing process, but can assist in coupling the pattern member 300a, 300b to the base plate 204. The second portion 344a, 344b has a specific geometry, as will be discussed below.

[0060] In the illustrated embodiment, the first pattern member 300a may be formed with a first interface and the second pattern member 300b may be formed with a second interface. Also, in the illustrated embodiment, the first interface of the first pattern member 300a is complementary to the second interface of the second pattern member 300b.

[0061] In the illustrated embodiment, the first portion 340a of the first pattern member 300a includes two projections 320. In the illustrated embodiment, one of the projections 320 defines a first portion of the first interface and the other of the projections 320 defines a second portion of the first interface. In the illustrated embodiment, the first portion 340b of the second pattern member 300a includes two hollow posts 330. In the illustrated embodiment, each of the hollow posts 330 may include a lip 334 extending from an outer surface thereof. In the illustrated embodiment, one of the hollow posts 330 defines a first portion of the second interface and the other of the hollow posts 330 defines a second portion of the second interface. The projectionsAttorney Docket No. 208273 -0012- WOO 1320 and hollow posts 330 having the respective interfaces, like the pattern members 300a, 300b, are formed via additive manufacturing.

[0062] The projections 320 are complementary to and configured to be received within a corresponding hollow post 330, as shown. In other embodiments, there may be more or fewer projections 320 corresponding to more or fewer hollow posts 330. Additionally, the shapes and sizes of the projections 320 and the hollow posts 330 are merely exemplary. The first and second interfaces may be defined by alternative structures in other embodiments.

[0063] In some embodiments, the projections 320 are received directly within the aperture 240 of the base plate 204 (i.e., without the intervening hollow posts 330) and are sized to directly engage the aperture 240. The pattern member 300a, 300b may be fixed to the base plate 204 by the interaction (e.g., friction fit, interference fit, etc.) with the projections 320 and the apertures 240. In other embodiments, the projections 320 function as locator pins to ensure correct placement and orientation of the pattern member 300a, 300b relative to the base plate 204. In some embodiments, an additional assembly step (e.g., an adhesive) may be used to further secure the pattern member 300a, 300b to the base plate 204.

[0064] Further with respect to step 116, the method further includes positioning the pattern members 300a, 300b within the respective recess 208a, 208b such that the first portion 340a, 340b of the pattern member 300a, 300b is positioned within the respective recess 208a, 208b and the second portion 344a, 344b of the pattern member 300a, 300b extends from the respective surface 204a, 204b of the base plate 204.

[0065] In some cases, the first portion 340a, 340b the pattern member 300a, 300b is sized and shaped to correspond to the entire or a portion of the respective recess 208a, 208b. For example, as illustrated, the first portion 340b of the second pattern member 300b has the same size and shape as the second recess 208b in which it is received. In other cases, the first portion 340a, 340b of the pattern member 300a, 300b is sized and shaped to correspond to only a portion of the recess 208a, 208b. For example, as illustrated, the first portion 340a of the first pattern member 300a is sized and shaped to occupy only a portion of the first recess 208a. In the illustrated embodiment, a third pattern member 300c, also formed via additive manufacturing like the first and second pattern members 300a, 300b, may be sized and shaped to be positionedAttorney Docket No. 208273 -0012- WOO 1 in the remaining portion of the first recess 208a, as shown. The first portions 340a, 340c of the first pattern member 300a and the third pattern member 300c may be positioned relative to and / or coupled to one another such that, collectively, they both fit within the first recess 208a. For example, the first portion 340c of the third pattern member 300c may have a shape that is complementary to a groove 348 in the first portion 340a of the first pattern member 300a such that a first pattern member 300a overlays the third pattern member 300c when both are positioned in the first recess 208a.

[0066] The pattern shown herein is merely illustrative. The pattern, on both sides of the base plate 204, may include any number of pattern members in any orientation. For example, in other embodiments, the first pattern member 300a may be sized and shaped to correspond to the entire first recess 208a. In still other embodiments, the first recess 208a may receive any suitable number of pattern members, in addition or alternatively, to the first and third pattern member 300a, 300c. Similarly, the second recess 208b may receive any suitable number of pattern members, in addition or alternatively, to the second pattern member 300b. In some embodiments, the pattern may be on one only one surface 204a, 204b of the base plate 204.

[0067] As noted above, the second portion 344a, 344b, 344c of each of the pattern members 300a, 300b, 300c has any suitable geometry collectively defining the pattern, which forms a mold cavity of the mold. Accordingly, the second portion 344a, 344b, 344c of each of the pattern members 300a, 300b, 300c alone, or in combination with other pattern members 300a, 300b, 300c, define the geometry for forming the corresponding portion of the mold cavity.

[0068] Further with respect to step 120, the pattern members 300a, 300b, 300c may be coupled to the base plate 204 within the corresponding recesses 208a, 208b. Preferably, the pattern members 300a, 300b, 300c are coupled to the base plate 204 within the corresponding recesses 208a, 208b with minimal or no fasteners, as noted above.

[0069] In the illustrated embodiment, the first pattern member 300a is coupled to the second pattern member 300b through the apertures 240 in the base plate 204. That is, as shown, the second pattern member 300b is positioned such that each of the first and second hollow posts 330 is inserted into a respective aperture 240 in the base plate 204. In some embodiments, the second interface of the second pattern member 300b may positively engage base plate 204. ForAttorney Docket No. 208273 -0012- WOO 1 example, in the illustrated embodiment, the lip 334 of each of the hollow posts 330 may be snap fit with the respective groove 250 surrounding the apertures 240. The first pattern member 300a is then positioned such that the first and second projections 320 are inserted into the respective hollow posts 330. The first and second projections 320 may be secured to the hollow posts 330 via positive engagement (e.g., a snap fit, a friction fit, etc.), adhesive (e.g., applied to the inner surfaces of the hollow posts and / or the surfaces of the projections), or both.

[0070] In the illustrated embodiment, the third pattern member 300c may be coupled between the base plate 204 and the first pattern member 300a. That is, the third pattern member 300c may be positioned within the first recess 208a prior to the first pattern member 300a being coupled to the second pattern member 300b. Accordingly, the third pattern member 300a may be positioned within the complementary groove 348 when the first pattern member 300a is properly positioned within the first recess 208a and after the first pattern member 300a is coupled to the second pattern member 300b. An adhesive may also be used between the base plate 204 and the third pattern member 300c and between the first pattern member 300a and third pattern member 300c.

[0071] In other embodiments, the first and second interfaces of the respective first and second pattern members 300a, 300b may be omitted and the first and second pattern members 300a, 300b may be adhesively coupled within the respective first and second recess 208b. In some embodiments, each of the first, second, and third pattern members 300a, 300b, 300c may be coupled to the respective recess using an adhesive. That is, in some cases, the adhesive may be applied to all or part of the first portion of the respective pattern member 300a, 300b, 300c and / or all or part of the respective recessed surface 220, 230, the walls 224, 234, or both to adhesively couple the pattern members 300a, 300b, 300c to the respective recess 208a, 208b. Additionally, as discussed above, the first and third pattern members 300a, 300c may be adhesively coupled to one another via adhesive on their mating surfaces. When present on the pattern members 300a, 300b, 300c, the geometric pattern is on the surface of the first portion 340a, 340b, 340c that mates with the recess 208a, 208b. Accordingly, the geometric pattern may better enable adhesive coupling between the pattern members 300a, 300b, and 300c and the base plate.Attorney Docket No. 208273 -0012- WOO 1

[0072] The adhesive can aid securing of the pattern member 300a, 300b, 300c to the base plate 204. The adhesive can be applied to the portions of the respective pattern members 300a, 300b, 300c, and / or all or part of the respective recessed surface 220, 230, the walls 224, 234, or any combination thereof as discussed above. The pattern member 300a, 300b, 300c can be positioned within the respective recessed surface 220, 230 and the adhesive can be allowed to cure for a period of time, thereby coupling the pattern member 300a, 300b, 300c to the base plate 204. Example adhesives include, but are not limited to, acrylate-based adhesives, methacrylate- based adhesives, and epoxide-based adhesives. An example acrylate-based adhesive includes, but is not limited to, 3M DP810.

[0073] Together with the rounded surfaces of the recesses 208a, 208b, the coupling of the pattern members 300a, 300b, 300c to one another through the base plate 204 or adhesively coupling the pattern members 300a, 300b, 300c to the base plate 204 reduces stress on the pattern members 300a, 300b, 300c that traditionally causes fracture, as compared to molds that are assembled using fasteners and having recesses with sharp edges.

[0074] As shown herein, the pattern members 300a, 300b, 300c are formed to contact or abut the walls 224 and the 234, such that there is minimal or no space therebetween. Accordingly, the pattern of the resulting tooling pattern plate 200 creates cavities (e.g., negative features) within the mold cavity. In still other embodiments, any of the pattern members 300a, 300b, 300c may include one or more recesses (not shown) or grooves (not shown) that may be used to create positive features (e.g., ridges, lips, flanges, projections, etc.) of the mold cavity. The recesses / grooves may have any suitable size and shape.

[0075] Additionally, in some embodiments, the method 100 may further include applying a ceramic coating to the tooling pattern plate 200. The ceramic coating may aid in the durability of the tooling pattern plate 200. In some embodiments, the ceramic coating may be applied to all or a portion of the base plate 204, all or a portion of the pattern members 300a, 300b, 300c, or both. The ceramic coating increases the hardness of the tooling pattern plate 200, particularly the pattern members 300a, 300b, 300c. Additionally, over time, the ceramic coating can be reapplied to maintain the hardness of the tooling pattern plate with successive use. The ceramic coatings may include combinations of multiple different engineering ceramics, refractory resins,Attorney Docket No. 208273 -0012- WOO 1 pigments, and other functional additives. Suitable example ceramic coatings include formulations from, but are not limited to, some CERAKOTE® oven-cured and air-cured products. In some embodiments, the ceramic coating is comprised of a suitable polymer system such as, but not limited to, a polyurethane, epoxy, acrylate, methyl or phenyl modified silicone, utilized as a matrix material to form a composite coating with engineering ceramics, such as but not limited to, alumina, zirconia, carbides, and nitrides.

[0076] In some embodiments, the method includes applying a second ceramic coating. The second ceramic coating can be applied to at least a portion (e.g., surface) of the ceramic coating. The description of the ceramic coating can also be applied to the second ceramic coating. Embodiments that include the ceramic coating and the second ceramic coating can be used to assess wear of the tooling pattern plate 200. For example, the ceramic coating can include a pigment, and the second ceramic coating can include a pigment that is different from the pigment of the ceramic coating. As the second ceramic coating experiences wear and is removed from the tooling pattern plate 200, the pigment of the ceramic coating will become more visible. The change of color can be used to assess wear of the ceramic coating(s) and inform a user when the tooling pattern plate 200 requires additional application of a ceramic coating.

[0077] Conventional tooling pattern plates are often made entirely via machining. The time required to create a conventional tooling pattern plate via machining alone is significant because small details of the tooling pattern plate are difficult to capture. Additionally, because the details are difficult to capture, mistakes during machining are common, and the cost to re-machine the tooling is considerable. In contrast, the disclosed method (using additive and subtractive manufacturing) and the resulting tooling pattern plate 200 is an easier, faster, and more cost effective production of the tooling pattern plate 200. This is because using machining for only the base plate 204 reduces the complexity of the machining process and using additive manufacturing for the pattern members (which include the details of the tooling pattern plate).

[0078] FIG. 5 illustrates a further embodiment utilizing the method described above with respect to FIGS. 1-4. In the embodiment illustrated in FIG. 5, the tooling pattern plate 504 includes a large recess 508a. The overall pattern member 500 formed within the large recess 508a includes a substantially flat plate 510 that fills the large recess 508a and a plurality ofAttorney Docket No. 208273 -0012- WOO 1 repeating pattern members 514 that extend outward from the plate 510, similar to the embodiment shown in FIGS. 1-4. In the illustrated embodiment, the repeating pattern members 514 follow an arrayed (e.g., a rectangular array) pattern, though in other embodiments, the arrangement may be different. Each of the repeating pattern members 514 is connected in a continuous, uninterrupted manner to one another via the plate portion 510. Projections (similar to projections 320) and, in some embodiments, hollow posts (similar to hollow posts 330) may be incorporated into the pattern member 500 in a manner similar as described above with respect to FIGS. 3-4. In some embodiments, only a single side of the tooling pattern plate 504 has such an overall pattern member. In the embodiment shown, each of the opposing sides of the plate 504 includes a recess 508a, 508b for a pattern member 500 as described.

[0079] Clauses

[0080] Clause 1. A method of manufacturing a sand casting hybrid tooling pattern plate, the tooling pattern plate used to form a mold from foundry sand, the method comprising: providing a base plate having a first surface and a second surface opposite the first surface; forming a recess in the first surface of the base plate; forming, via additive manufacturing, a pattern member; positioning the pattern member within the recess such that a first portion of the pattern member is positioned within the recess and a second portion of the pattern member extends from the first surface of the base plate; and coupling the pattern member to the base plate.

[0081] Clause 2. The method of clause 1, wherein forming the recess in the first surface of the base plate includes forming the recess in the first surface via machining.

[0082] Clause 3. The method of clause 2, wherein the base plate comprises a metal.

[0083] Clause 4. The method of clause 3, wherein the metal comprises aluminum, a magnesium alloy, cast iron, or steel.

[0084] Clause 5. The method of clause 1, wherein forming, via additive manufacturing, the pattern member includes forming, via additive manufacturing, the pattern member from a photopolymer.Attorney Docket No. 208273 -0012- WOO 1

[0085] Clause 6. The method of clause 5, wherein the photopolymer has an elongation at break of at least 3%.

[0086] Clause 7. The method of clause 5, wherein the photopolymer has a heat deflection temperature at 0.455 MPa of at least 100 °F.

[0087] Clause 8. The method of clause 5, wherein the photopolymer has a hardness of 85D.

[0088] Clause 9. The method of clause 1, wherein coupling the pattern member to the base plate includes coupling the pattern member within the recess via an adhesive.

[0089] Clause 10. The method of clause 1, wherein the recess is a first recess and the pattern member is a first pattern member, and further comprising: forming a second recess in the second surface of the base plate; forming, via additive manufacturing, a second pattern member; and positioning the second pattern member within the second recess such that a first portion of the second pattern member is positioned within the second recess and a second portion of the second pattern member extends from the second surface of the base plate.

[0090] Clause 11. The method of clause 10, wherein coupling the first pattern member within the first recess includes coupling the pattern member within the first recess via an adhesive and further comprising coupling the second pattern member to the base plate by coupling the second pattern member within the second recess via the adhesive.

[0091] Clause 12. The method of clause 10, wherein forming the first recess and the second recess includes creating an aperture that extends through the base plate between the first recess and the second recess, wherein forming, via additive manufacturing, the first pattern member and the second pattern member includes forming, via additive manufacturing, the first pattern member with a first interface and the second pattern member with a second interface that is complementary to the first interface, and wherein positioning the first pattern member within the first recess includes positioning the first interface through the aperture and positioning the second pattern member within the second recess includes engaging the second interface with the first interface of the first pattern member.Attorney Docket No. 208273 -0012- WOO 1

[0092] Clause 13. The method of clause 10, wherein forming the first recess and the second recess includes creating an aperture that extends through the base plate between the first recess and the second recess, and further comprising coupling the first pattern member to the second pattern member through the aperture in the base plate.

[0093] Clause 14. The method of clause 1, wherein the pattern member is a first pattern member, and further comprising forming, via additive manufacturing, a second pattern member; and positioning the second pattern member within the recess such that a first portion of the second pattern member is positioned within the recess and a second portion of the second pattern member extends from the first surface of the base plate.

[0094] Clause 15. The method of clause 14, wherein the second pattern member is coupled between the first pattern member and the base plate.

[0095] Clause 16. The method of clause 1, further comprising applying a ceramic coating on at least a portion of the base plate, at least a portion of the pattern member, or both.

[0096] Clause 17. The method of clause 16, wherein the ceramic coating is derived from a polymer system selected from the group consisting of a polyurethane, an epoxy, an acrylate, a methyl or phenyl modified silicone, and any of the foregoing further comprising an engineering ceramic.

[0097] Clause 18. The method of clause 1, wherein coupling the pattern member to the base plate includes coupling the pattern member to the base plate without fasteners.

[0098] Clause 19. A sand casting hybrid tooling pattern plate, the tooling pattern plate used to form a mold from foundry sand, the tooling pattern plate comprising: a metal base plate including a first surface, a second surface opposite the first surface, and a recess in the first surface; and a photopolymer pattern member positioned within the recess, a portion of the photopolymer pattern member extending from the first surface.

[0099] Clause 20. The sand casting hybrid tooling pattern plate of clause 19, wherein the photopolymer has an elongation at break of at least 3%.Attorney Docket No. 208273 -0012- WOO 1

[0100] Clause 21. The sand casting hybrid tooling pattern plate of clause 19, wherein the photopolymer has a heat deflection temperature at 0.455MPa of at least 100 °F.

[0101] Clause 22. The sand casting hybrid tooling pattern plate of clause 19, wherein the photopolymer has a hardness of 85D.

[0102] Clause 23. The sand casting hybrid tooling pattern plate of clause 19, wherein the metal comprises aluminum, a magnesium alloy, cast iron, or steel.

[0103] Clause 24. The sand casting hybrid tooling pattern plate of clause 19, further comprising adhesive between the photopolymer pattern member and a surface of the recess.

[0104] Clause 25. The sand casting hybrid tooling pattern plate of clause 19, wherein the recess is a first recess and the photopolymer pattern member is a first photopolymer pattern member, wherein the metal base plate further includes a second recess in the second surface, and further comprising a second photopolymer pattern member positioned within the second recess, a portion of the second photopolymer pattern member extending from the second surface.

[0105] Clause 26. The sand casting hybrid tooling pattern plate of clause 25, further comprising an adhesive between the first photopolymer pattern member and a surface of the first recess and an adhesive between the second photopolymer pattern member and a surface of the second recess.

[0106] Clause 27. The sand casting hybrid tooling pattern plate of clause 26, further comprising an aperture extending through the metal base plate from the first recess to the second recess, and wherein the first pattern member is coupled to the second pattern member through the aperture.

[0107] Clause 28. The sand casting hybrid tooling pattern plate of clause 27, wherein the photopolymer pattern member is a first photopolymer pattern member, and further comprising a second photopolymer pattern member positioned within the recess, a portion of the second photopolymer pattern member extending from the first surface.Attorney Docket No. 208273 -0012- WOO 1

[0108] Clause 29. The sand casting hybrid tooling pattern plate of clause 19, further comprising a ceramic coating applied to at least a portion of the base plate, at least a portion of the pattern member, or both.

[0109] Clause 30. The sand casting hybrid tooling pattern plate of clause 29, wherein the ceramic coating is derived from a polymer system selected from the group consisting of a polyurethane, an epoxy, an acrylate, a methyl or phenyl modified silicone, and any of the foregoing further comprising an engineering ceramic.

[0110] Clause 31. The sand casting hybrid tooling pattern plate of clause 19, wherein the photopolymer pattern member is coupled to the metal base plate without fasteners.200) is faster and easier. Accordingly, the disclosed method and the resulting tooling pattern plate 200 allows for a reduction in raw materials costs, due to reducing required input starting material for machining portions of the assembly. Additionally, there is reduced labor and machine-time requirement to produce machined portions of the assembly, due to moving complex features to parts produced by additive manufacturing. That is, advantages include smaller machining stock pieces (less waste) and reduced machining time. Even further, modularity of the pattern members, allows for easier iterative upgrades / modifications to improve tooling pattern plate 200 design or with end-product design, and replacement in the case of failures.

[0111] Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the invention as described.

[0112] Various features of the invention are set forth in the following claims.

Claims

Attorney Docket No. 208273 -0012- WOO 1CLAIMSWhat is claimed is:

1. A method of manufacturing a sand casting hybrid tooling pattern plate , the tooling pattern plate used to form a mold from foundry sand, the method comprising: providing a base plate having a first surface and a second surface opposite the first surface; forming a recess in the first surface of the base plate; forming, via additive manufacturing, a pattern member; positioning the pattern member within the recess such that a first portion of the pattern member is positioned within the recess and a second portion of the pattern member extends from the first surface of the base plate; and coupling the pattern member to the base plate.

2. The method of claim 1, wherein forming the recess in the first surface of the base plate includes forming the recess in the first surface via machining.

3. The method of claim 2, wherein the base plate comprises a metal.

4. The method of claim 3, wherein the metal comprises aluminum, a magnesium alloy, cast iron, or steel.

5. The method of claim 1, wherein forming, via additive manufacturing, the pattern member includes forming, via additive manufacturing, the pattern member from a photopolymer.

6. The method of claim 5, wherein the photopolymer has an elongation at break of at least ^ 30 / zo.

7. The method of claim 5, wherein the photopolymer has a heat deflection temperature at 0.455 MPa of at least 100 °F.

8. The method of claim 5, wherein the photopolymer has a hardness of about 85D.

9. The method of claim 1, wherein coupling the pattern member to the base plate includes coupling the pattern member within the recess via an adhesive.Attorney Docket No. 208273 -0012- WOO 110. The method of claim 1, wherein the recess is a first recess and the pattern member is a first pattern member, and further comprising: forming a second recess in the second surface of the base plate; forming, via additive manufacturing, a second pattern member; and positioning the second pattern member within the second recess such that a first portion of the second pattern member is positioned within the second recess and a second portion of the second pattern member extends from the second surface of the base plate.

11. The method of claim 10, wherein coupling the first pattern member within the first recess includes coupling the pattern member within the first recess via an adhesive and further comprising coupling the second pattern member to the base plate by coupling the second pattern member within the second recess via the adhesive.

12. The method of claim 10, wherein forming the first recess and the second recess includes creating an aperture that extends through the base plate between the first recess and the second recess, wherein forming, via additive manufacturing, the first pattern member and the second pattern member includes forming, via additive manufacturing, the first pattern member with a first interface and the second pattern member with a second interface that is complementary to the first interface, and wherein positioning the first pattern member within the first recess includes positioning the first interface through the aperture and positioning the second pattern member within the second recess includes engaging the second interface with the first interface of the first pattern member.

13. The method of claim 10, wherein forming the first recess and the second recess includes creating an aperture that extends through the base plate between the first recess and the second recess, and further comprising coupling the first pattern member to the second pattern member through the aperture in the base plate.

14. The method of claim 1, wherein the pattern member is a first pattern member, and further comprising forming, via additive manufacturing, a second pattern member; andAttorney Docket No. 208273 -0012- WOO 1 positioning the second pattern member within the recess such that a first portion of the second pattern member is positioned within the recess and a second portion of the second pattern member extends from the first surface of the base plate.

15. The method of claim 14, wherein the second pattern member is coupled between the first pattern member and the base plate.

16. The method of claim 1, further comprising applying a ceramic coating on at least a portion of the base plate, at least a portion of the pattern member, or both.

17. The method of claim 16, wherein the ceramic coating is derived from a polymer system selected from the group consisting of a polyurethane, an epoxy, an acrylate, a methyl or phenyl modified silicone, and any of the foregoing further comprising an engineering ceramic.

18. The method of claim 1, wherein coupling the pattern member to the base plate includes coupling the pattern member to the base plate without fasteners.

19. A sand casting hybrid tooling pattern plate , the tooling pattern plate used to form a mold from foundry sand, the tooling pattern plate comprising: a metal base plate including a first surface, a second surface opposite the first surface, and a recess in the first surface; and a photopolymer pattern member positioned within the recess, a portion of the photopolymer pattern member extending from the first surface.

20. The sand casting hybrid tooling pattern plate of claim 19, wherein the photopolymer has an elongation at break of at least 3%.

21. The sand casting hybrid tooling pattern plate of claim 19, wherein the photopolymer has a heat deflection temperature at 0.455MPa of at least 100 °F.

22. The sand casting hybrid tooling pattern plate of claim 19, wherein the photopolymer has a hardness of about 85D.

23. The sand casting hybrid tooling pattern plate of claim 19, wherein the metal comprises aluminum, a magnesium alloy, cast iron, or steel.Attorney Docket No. 208273 -0012- WOO 124. The sand casting hybrid tooling pattern plate of claim 19, further comprising adhesive between the photopolymer pattern member and a surface of the recess.

25. The sand casting hybrid tooling pattern plate of claim 19, wherein the recess is a first recess and the photopolymer pattern member is a first photopolymer pattern member, wherein the metal base plate further includes a second recess in the second surface, and further comprising a second photopolymer pattern member positioned within the second recess, a portion of the second photopolymer pattern member extending from the second surface.

26. The sand casting hybrid tooling pattern plate of claim 25, further comprising an adhesive between the first photopolymer pattern member and a surface of the first recess and an adhesive between the second photopolymer pattern member and a surface of the second recess.

27. The sand casting hybrid tooling pattern plate of claim 26, further comprising an aperture extending through the metal base plate from the first recess to the second recess, and wherein the first pattern member is coupled to the second pattern member through the aperture.

28. The sand casting hybrid tooling pattern plate of claim 19, wherein the photopolymer pattern member is a first photopolymer pattern member, and further comprising a second photopolymer pattern member positioned within the recess, a portion of the second photopolymer pattern member extending from the first surface.

29. The sand casting hybrid tooling pattern plate of claim 19, further comprising a ceramic coating applied to at least a portion of the base plate, at least a portion of the pattern member, or both.

30. The sand casting hybrid tooling pattern plate of claim 29, wherein the ceramic coating is derived from a polymer system selected from the group consisting of a polyurethane, an epoxy, an acrylate, a methyl or phenyl modified silicone, and any of the foregoing further comprising an engineering ceramic.

31. The sand casting hybrid tooling pattern plate of claim 19, wherein the photopolymer pattern member is coupled to the metal base plate without fasteners.

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