Casting system and method for manufacturing objects using the casting system in confined spaces

Abstract

The present invention provides a casting system (100, 200, 300, 400, 500), in particular an investment casting system, for manufacturing objects in confined spaces, the casting system (100, 200, 300, 400, 500) comprising a main casing, and a catalytic unit (206, 306) housed within the main casing or attached to the main casing, wherein the catalytic unit (206, 306) is configured to treat exhaust gasses (219, 319) by removing harmful components generated during operation, and wherein the main casing comprises dimensions suitable for portability and storage in confined spaces. The present invention further provides a method of manufacturing objects using the casting system according to the present invention.

Description

[0001] DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0002] - 1 -

[0003] CASTING SYSTEM AND METHOD FOR MANUFACTURING OBJECTS USING THE CASTING SYSTEM IN CONFINED SPACES

[0004] The present invention relates to a casting system and method for performing an investment casting for manufacturing objects in confined spaces, such as domestic environments or compact environments.

[0005] Manufacturing delicate metallic objects, such as jewellery, intricate components, or prototypes, often requires precise and controlled casting processes. Traditional casting systems are typically designed for industrial settings, where adequate ventilation, large-scale equipment, and extensive safety measures are readily available. However, these systems pose significant challenges when used in confined spaces, such as household environments, where such resources are limited or environments such as workshops or maintenance areas, where exhaust emissions are critical and must be minimized or limited.

[0006] One major drawback of existing casting systems is the release of toxic emissions, which can harm users and contaminate the surrounding areas. This is particularly problematic in small spaces with limited airflow. Additionally, conventional systems often lack compact, user-friendly designs that can ensure both ease of use and high- quality results in such environments. These issues create a demand for a novel approach that combines safety, efficiency, and environmental compliance for household-scale metallic casting.

[0007] It is therefore an object of the present invention to provide an improved casting system specifically designed to enhance the manufacturing of delicate metallic objects in confined spaces, such as household environments or spaces in which exhaust gases are critical and must be limited. Advantageously, the casting system of the present invention ensures environmental compliance and protects users and surrounding areas from exposure to toxic emission.

[0008] This object is achieved in the present invention by a casting system, in particular an investment casting system, for manufacturing (metallic) objects in confined spaces. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0009] - 2 -

[0010] The casting system comprising:

[0011] - a main casing, and

[0012] - a catalytic unit housed within the main casing or attached to the main casing, wherein the catalytic unit is configured to treat exhaust gasses by removing harmful components generated during operation, and wherein the main casing comprises dimensions suitable for portability and storage in confined spaces.

[0013] The invention is based on the basic idea to provide a casting system, in particular an investment casting system, for manufacturing metallic objects in confined spaces, such as domestic, household or compact environments. The system is configured for a precision manufacturing process that enables the creation of complex, detailed metallic objects with intricate shapes and high accuracy. The casting system comprises a catalytic unit for treating exhaust gas generated during operation of the casting system. In particular, the casting system comprises a main casing (or an outer housing) constructed to accommodate the catalytic unit. Advantageously, the main casing is configured to encompasses all components required to perform casting process, such as heating, melting, burning out and catalytic processes. The casting system is advantageously designed with a robust and compact structure (having a compact casing), thereby ensuring durability and efficient use of space.

[0014] In particular, the casting system further comprises a melting furnace configured to melt metals, and a burn-out furnace configured to heat a casting mould for removing a positive model (or pattern) disposed in the casting mould, wherein the main casing is further configured to house the melting furnace unit and the burn-out furnace, preferably the melting furnace is positioned upstream from the burn-out furnace.

[0015] In particular, the main casing comprises a first chamber, a second chamber and a connecting unit for fluidly connecting the first and second chambers, wherein the second chamber is configured to enclose the catalytic unit, wherein the first chamber is configured to enclose a melting furnace and a burn-out furnace of the casting DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0016] - 3 - system, and wherein the connecting unit comprises a gas channel for transferring gasses between the first and second chambers in a sealed manner.

[0017] In particular, the casting system further comprises at least one pressure unit configured to introduce fresh gas, preferably air, into the casting system, preferably a first chamber.

[0018] In particular, the fresh gas delivered from the at least one pressure unit is configured to be guided to the second chamber.

[0019] In particular, the system further comprises at least one suction unit configured to evacuate the casting system, preferably a first chamber and / or a second chamber.

[0020] In particular, the at least one pressure unit the at least one suction unit is configured to be connected to a first chamber of the casting system.

[0021] In particular, the at least one pressure unit is configured to be connected to a first chamber of the casting system.

[0022] In particular, the at least one pressure unit comprises a first pressure unit configured to deliver fresh gas from a side of the first chamber located toward the upper end along the longitudinal direction, and / or a second pressure unit configured to deliver fresh gas from a side of the first chamber located toward the lower end along the longitudinal direction.

[0023] In particular, a first pressure unit configured to deliver fresh gas close (near) to a melting furnace, and a second pressure unit is configured to deliver fresh gas close to a burn-out furnace.

[0024] In particular, the casting system further comprise valve elements configured to control the flow of gases into or out of the casting system, wherein the valve elements are configured to be connected to the at least one pressure unit. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0025] - 4 - ln particular, valve elements are configured to be connected to the at least one pressure unit.

[0026] In particular, a first valve element is configured to be connected to a first pressure unit.

[0027] In particular, a second valve element is configured to be connected to a first suction unit.

[0028] In particular, a third valve element is configured to be connected to a second pressure unit.

[0029] In particular, the casting system further comprises an evaporation unit configured to remove excess moisture from the treated (cleaned) exhaust gas, wherein the evaporation unit is configured to be attached to the exterior of the main casing or is enclosed by the main casing.

[0030] Advantageously the evaporation unit is configured to remove water contents from the cooled and treated exhaust gases.

[0031] In particular, the main casing (or outer housing) comprises a compact size configured to be placed on surfaces, such as desks, shelves, or countertops.

[0032] In particular, the term "main casing" refers to the primary structural component that houses and protects the internal parts of the casting system. It serves as the physical boundary, ensuring that all components are securely enclosed, provides protection from external damage, and contributes to the portability and usability of the casting system.

[0033] In particular, the casting system further comprises a melting furnace configured to melt metals, and a burn-out furnace configured to heat a casting mould for removing (burning out) a positive model disposed (embedded) in the casting mould, wherein the main casing is further configured to house (or enclose or accommodate) the melting furnace unit and the burn-out furnace. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0034] - 5 - ln particular, the main casing comprises a first chamber, a second chamber and a connecting unit for fluidly connecting the first and second chambers.

[0035] In particular, the melting furnace and the burn-out furnace are configured to be positioned in the first chamber, and the catalytic unit configured to be positioned in the second chamber, wherein the connecting unit comprises a gas channel for transferring gasses between the first and second chambers in a sealed manner.

[0036] In particular, the casting system, e.g. the main casing including a first chamber and a second chamber, is configured to be operated under vacuum, overpressure or atmospheric conditions.

[0037] In particular, the casting system, e.g. the catalytic unit, further comprises a filter unit, in particular a particulate filter, configured to capture and remove particulate matter from the exhaust gas.

[0038] In particular, the particulate filter is configured to be positioned in the catalytic unit.

[0039] In particular, the catalytic unit further comprises a catalyst material.

[0040] In particular, the catalyst material comprises metals or mixed metal oxides dispersed or coated onto a onto a porous substrate or a support material, preferably the porous substrate comprises porous ceramics, such as alumina (AI2O3), silica (SiO2), zeolites, or ceramic-based materials, and support material comprises metallic materials.

[0041] In particular, the metals or mixed metal oxides comprise platinum (Pt), rhodium (Rh), and palladium (Pd) and the like.

[0042] Advantageously the catalyst material is configured to convert harmful emissions like NOx, CO, and HCs into harmless substances (such as N2, CO2, and H2O). DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0043] - 6 - ln particular, the casting system further comprises heating elements for heating the melting furnace, the burn-out furnace and the catalytic unit,

[0044] In particular, the melting furnace comprises a first heating element, and / or the catalytic unit comprises a second heating element, and / or the burn-out furnace comprises a third heating element positioned on a lower side of the casting mould and a fourth heating element positioned on an upper side of the casting mould.

[0045] In particular, a first heating element is positioned in the melting furnace, a second heating element is positioned in the catalytic unit, and a third heating element is positioned in the burn-out furnace.

[0046] In particular, the burn-out furnace comprises a fourth heating element, wherein the fourth heating element is disposed at an upper side of burn-out furnace and the third heating elements is disclosed at a lower side of the burn-out furnace.

[0047] In particular, a casting mould is disposed between the forth and third heating elements in a longitudinal direction.

[0048] In particular, a burn-out furnace is configured to heat a casting mould to elevated temperatures, facilitating the removal of a positive model or pattern, typically made of wax or another material, through a controlled burn-out process. This process ensures the complete elimination of the positive model. After the burn-out process a clean, hollow cavity within the casting mould is remained. This mould cavity is used for the subsequent metal casting process.

[0049] In particular, the burn-out furnace is configured to maintain precise temperature control to ensure efficient and uniform heat distribution throughout the mould. This in turn enables optimal burn-out performance and prevents damage to the mould.

[0050] In particular, the system is configured to be used for performing heat treatment processes. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0051] - 7 - ln particular, the burn-out furnace can be utilized for heat treatment of parts either to increase mechanical properties or to reduce residual stresses and component distortion.

[0052] Advantageously, the burn-out furnace can be used for the heat treatment of parts that have already been cast and removed from the mould for increasing their mechanical properties. The parts can then be put back into the burn-out furnace.

[0053] Parts made of aluminium alloys, for example, can be treated by solution annealing at temperatures ranging from 400 to 550 °C using the burn-out furnace.

[0054] Quenching of the part can be performed manually, by removing it from the burn-out furnace and quickly cool it for example in water.

[0055] In a further step, the component can be aged in the burnout unit at temperatures of around 100-200 °C in order to achieve the T6 state for aluminium alloys such as AW- 6061 or AW-7075. This leads to a significant improvement in the mechanical properties of the component.

[0056] The computing device of the system can alert the user to the optimum removal time via visual, acoustic or other signals. It can also control the appropriate temperatures or temperature curves for the specific material. The process can be used for different kinds of materials including different alloys based on e.g. iron, copper, nickel or titanium by adapting it to the appropriate temperatures.

[0057] It is particularly advantageous to use the burn-out furnace for this treatment, as no separate oven is required.

[0058] Advantageously, the burn-out furnace can be used for heat treatment in order to reduce residual stresses in the cast parts. Residual stresses can occur during solidification and cooling of cast components, particularly due to inhomogeneous temperature distributions, and can lead to distortion. One method to prevent or minimize this is to reheat the casting mould after the melt has completely solidified. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0059] - 8 -

[0060] This allows residual stresses in the component to be relieved (stress relief annealing). During this process, the component is supported by the surrounding mould, which preserves the geometry. Before stress relief annealing, both the component and the mould are deformed. These deformations are reduced or completely eliminated during stress relief annealing.

[0061] The temperature required for this treatment varies depending on the material and is below the melting point. A temperature range of 300 to 550 °C is suitable for aluminium alloys. The process can be used for different kinds of materials including different alloys based on e.g. zinc, iron, copper, nickel or titanium by adapting it to the appropriate temperatures.

[0062] It is particularly advantageous to use the burn-out furnace for this treatment, as it can be automatically controlled by the systems computer device after the casting process. In particular, the catalytic unit configured to perform catalytic oxidation reaction of harmful components such as carbon monoxide and hydrocarbons.

[0063] In particular, the catalyst material comprises precious metals like platinum, palladium, and rhodium. in particular, a particulate filter configured to capture and remove particulate matter (PM) such as soot from the exhaust gases

[0064] In particular, the particulate filter comprises a porous structure that allows exhaust gases to pass through while trapping the solid particulate matter. The filter is made from materials like ceramic or cordierite, which can withstand high temperatures.

[0065] In particular, the catalytic unit is configured to be regenerated by a reverse gas flow from the catalytic unit toward a burn-out furnace, wherein the reverse gas flow is configured to be created: by activating at least one suction unit and by simultaneously opening a second valve element to environment to thereby create a continuous reverse gas flow; or DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0066] - 9 - by introducing a pressurized gas flow into an outlet of a catalytic unit using a pressure unit to thereby create a continuous reverse gas flow from; or by generating an intermittent reverse gas flow through evacuating, using at least one suction unit, the casting system; thereafter, opening a second valve element to allow ambient air to enter the evacuated casting system, thereby creating a high-pressure differential;

[0067] In particular, the catalytic unit, preferably the filter unit and the catalyst material, is configured to be regenerated using a regeneration method.

[0068] In particular, the regeneration method employs a reverse gas flow, from the catalytic unit toward the burn-out furnace, to remove contaminants.

[0069] In particular, the reverse gas flow can be created through several methods: applying a continuous reverse gas flow using a suction unit, introducing a continuous reverse gas flow with a pressure unit, or employing an intermittent reverse gas flow using a suction unit.

[0070] In particular, in the intermittent reverse gas flow method, the casting system is first evacuated to create a vacuum. Once evacuated, ambient air is allowed to rush into the casting system via a valve element, producing a high-pressure differential. This sudden influx of air generates a strong reverse flow that effectively dislodges (removes) embedded particles. The loosened contaminants are then transported to the burn-out furnace (in the first chamber) and / or removed by a suction unit.

[0071] Unlike conventional regeneration methods, the process described herein can be conducted at lower temperatures, thereby minimizing the risk of damage to the thermal insulation within the casting system while ensuring effective cleaning.

[0072] In particular, the casting system, e.g. a melting furnace, further comprises a filtering medium or a flexible enclosure for retaining and containing raw materials (i.e. the metallic materials to be melted). DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0073] - 10 -

[0074] In particular, the filtering medium configured to be positioned in a melting container, wherein the filter medium is configured to retain solid casting materials and filter out solid contaminants from the molten casting materials during operation of the casting system.

[0075] In particular, the filtering medium comprises a mesh or sleeve made of temperature- resistant fabric, such as fiberglass or silicate, particularly calcium-magnesium-silicate.

[0076] During the melting process, the molten material can flow freely through the openings of the filtering medium, while solid components, such as aluminium dross or slag, are trapped inside the filtering medium. This design helps prevent the accumulation of unwanted solid particles in the molten metal, which could otherwise compromise the quality of the cast.

[0077] By retaining the solid contaminants within the filtering medium, the subsequent cleaning of the melting container of the melting furnace has been simplified and the need for manual scraping or extensive cleaning processes have been reduced.

[0078] Additionally, the filtering medium protects the melting container from potential damage caused by the adherence of dross or slag, which can cause wear and tear over time.

[0079] In particular, the casting system further comprises a mixing mechanism configured to homogenise casting materials and / or incorporate various additives, such as silicon carbide nanoparticles, during the melting process in a melting furnace.

[0080] Advantageously, the mixing mechanism ensures effective integration of additives, contributing to grain refinement, which enhances the strength and overall performance of the manufactured object.

[0081] In particular, the mixing mechanism comprises a stirring unit that is configured to be operably connected to a melting furnace of the casting system. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0082] - 11 -

[0083] In particular, the casting system further comprises a dosing unit configured to introduce additives into the melting furnace during the melting process.

[0084] In particular, the mixing mechanism can be implemented by a unit configured to rotate or move a melting container induce mixing of casting materials.

[0085] Alternatively, the mixing mechanism can be implemented by a unit configured to rotate or move a stopper element of a melting container to thereby facilitate stirring of the melt.

[0086] Yet another way to implement the mixing mechanism comprises a vibration-based mechanism. Vibrations are introduced using a unit comprising ultrasound or piezoelectric actuators to induce mixing of the melt.

[0087] In particular, the mixing mechanism comprises electromagnetic stirring.

[0088] For example, the Lorentz force is utilized to stir the molten metal without physical contact. This mixing method combines electric currents and magnetic fields to induce flow within the melt. This in turn promotes uniform mixing and temperature distribution.

[0089] In particular, the mixing mechanism can be implemented by a stirring unit coupled to a melting furnace of a casting system.

[0090] In particular, the stirring unit comprises a flexible mixing element. This results in a compact stirring unit and efficient mixing of casting materials.

[0091] In particular, the mixing element comprises durable materials such as silicate, particularly calcium-magnesium-silicate, or other high-temperature resistant fibres like fiberglass or ceramic fibres.

[0092] In particular, the stirring unit further comprises a stirring weight, preferably comprising ceramics or metals. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0093] - 12 -

[0094] In particular, the stirring weight is configured to be affixed to an end of the mixing element to aid immersion and ensure consistent mixing throughout the melt.

[0095] In particular, the compact stirring unit according to the present invention not only provides effective homogenization but also ensures that additives are well-dispersed, contributing to a uniform and improved final object.

[0096] In particular, the casting system is configured to recirculate the treated exhaust gasses into the casting system.

[0097] In particular, the casting system further comprises a computing device configured to control the operation of the casting system and to perform a method of manufacturing objects using the casting system.

[0098] The computer device, for example, comprises a personal computer or a user interface device coupled to the casting of the casting system.

[0099] In particular, the present invention relates to a method of manufacturing objects using a casting system according to the present invention, wherein the method comprises the steps of: optionally, curing the casting mould in the burn-out furnace, preferably also removing potential condensates; optionally, drying the casting mould using the third and / or fourth heating elements, wherein the casting mould comprises a positive model and is positioned in the burn-out furnace, and more optionally, at the same time preheating the catalytic unit using the second heating element to a first temperature (e.g. 700°C to 1000°C) required for catalytic processes; heating the burn-out furnace to a second temperature (e.g. 500°C to 900°C) required for a subsequent burning step; burning out a positive model for a specific time while treating exhaust gas generated during burning process in the catalytic unit cooling down the casting mould to a third temperature (e.g. 150°C to 700°) lower than the second temperature while preheating the melting furnace; DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0100] - 13 - heating the melting furnace to a fourth temperature required for melting casting materials within the melting container; optionally, evacuating the casting system (e.g. the first and second chambers) using the first suction unit, preferably the second and third valve elements are in a closed sate; activating the fourth heating element (e.g. 300°C to 700°) for heating an upper side of the burn-out furnace, thereby creating a temperature gradient along the longitudinal direction of the casting mould (e.g. in the direction of the gravity); casting the molten casting materials into the casting mould by opening the closure element of the melting container; optionally, pressurizing the first chamber by opening the third valve element; deactivating the fourth heating element after a given period of time allowing for cooling off the casted object; and optionally, monitoring operational parameters such as temperatures, pressures, currents.

[0101] In particular, the present invention further relates to a non-transitory computer- readable medium configured to store program code which, when executed, is operative to cause a processor to perform a method of manufacturing objects using the casting system according to the present invention.

[0102] The present invention further relates to a method for regenerating a catalytic unit in a casting system using a continuous reverse gas flow, the method comprising the steps of:

[0103] - initiating a reverse flow by activating a suction unit (e.g. a vacuum pump) and by opening a valve element to create a steady gas flow (e.g. airflow) in a reverse direction to carry contaminants away from the catalytic unit; or

[0104] - introducing a pressurized gas (e.g. air) into an outlet of the catalytic unit using a pressure unit (e.g. a pressure pump), wherein the pressure unit is configured to generate a continuous reverse gas flow (e.g. from the catalytic unit toward the burnout furnace) for removing contaminants from the catalytic unit. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0105] - 14 -

[0106] In particular, the method further comprises the step of directing the contaminants removed from the catalytic unit toward a burn-out furnace.

[0107] In particular, the method further burning the loosened contaminants in a burn-out furnace.

[0108] In particular, the method is performed under controlled temperature conditions to prevent damage to the components of the casting system.

[0109] In particular, the method further comprises the step of monitoring the regeneration process with sensors to assess the efficiency of contaminant removal and the overall performance of the catalytic unit.

[0110] The present invention further relates to a method for regenerating a catalytic unit in a casting system using an intermittent reverse gas flow, the method comprising the steps of:

[0111] - evacuating, using a first suction unit, the casting system including the catalytic unit to create a vacuum state within the casting system;

[0112] - opening a valve element to allow ambient air to enter the casting system, thereby creating a high-pressure differential and generating an intermittent reverse gas flow;

[0113] - allowing the intermittent reverse gas flow to pass through the catalytic unit, effectively loosening embedded particles and contaminants;

[0114] - transporting (or guiding) the loosened contaminants toward a burn-out furnace; and

[0115] - burning the contaminant in the burn-out furnaces and / or suctioning the contaminants using a suction unit to remove them from the casting system.

[0116] The present invention further relates to a regeneration system for a catalytic unit in a casting system, the regeneration system comprising:

[0117] - preferably at least one suction unit configured to evacuate the casting system;

[0118] - at least one pressure unit configured to supply pressurized gas into the catalytic unit to create a reverse flow from the catalytic unit toward a burn-out furnace; and DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0119] - 15 -

[0120] - a valve arrangement operatively connected to the catalytic unit, the at least one suction unit, and the at least one pressure unit,

[0121] - the valve arrangement configured to open during operation of the at least one suction unit to allow a steady airflow into the casing system in the reverse direction, thereby carrying contaminants away from the catalytic unit, or

[0122] - the valve arrangement being configured to selectively allow ambient air to enter the evacuated casting system to create an intermittent high-pressure differential for removing embedded particles within the catalytic unit.

[0123] In particular, the pressure unit comprises a pressure pump used in the casting system, which is adapted to provide a continuous reverse gas flow into the catalytic unit.

[0124] In particular, the valve arrangement includes at least one selectively operable valve configured to introduce ambient air into the evacuated casting system.

[0125] In particular, a filter is positioned upstream of the suction unit to capture dislodged contaminants and prevent damage to the suction unit.

[0126] In particular, the catalytic unit includes a particle filter and catalyst material configured to undergo reverse flow regeneration without structural damage.

[0127] In particular, the high-pressure differential generated during the intermittent reverse flow achieves a peak airflow sufficient to loosen fine particulate contaminants embedded within the catalytic unit.

[0128] In particular, the present invention further pertains to a device for manufacturing a casting mould, wherein the device comprises:

[0129] - a housing (e.g. a mould container) defining an interior space configured to enclose a positive model,

[0130] - the housing comprising a first end, a second end, and a slit extending along a longitudinal direction from the first end to the second end, and

[0131] - the slit being configured to facilitate the opening or access to the interior space of the housing. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0132] - 16 -

[0133] In particular, the positive model is a model of an object to be manufactured by the casting process.

[0134] In particular, the housing exhibits localized flexibility facilitated by a slit extending along its surface. This enables elastic deformation to temporarily alter the dimensions of the housing while maintaining structural integrity.

[0135] In particular, the slit is configured to create a gap or separation (e.g., between two halves of the housing) to enlarge the housing, thereby allowing for the easy removal of the manufactured casting mould.

[0136] In particular, a device for manufacturing a casting mould includes a securing element configured to hold the housing slit in either a first position (e.g., compressed or normal state), defining a first volume of the housing, or a second position (e.g., stretched or activated state), defining a second, larger volume of the housing. This mechanism facilitates the detachment of the housing from the moulding compound, allowing for the easy removal of the fabricated mould.

[0137] For example, the securing element comprises a flexible material (e.g. a rubber sealing element) or a mechanical element (e.g., clamps, latches, fasteners, springs).

[0138] Advantageously, the removal or disengagement of the securing element allows the slit to be expanded, enlarging the volume (the interior space) of the housing.

[0139] In particular, a device for manufacturing a casting mould further comprises a base lid, wherein the base lid configured to be attached to the housing, at a second end of the housing, through a mechanical connection (e.g. threaded connection).

[0140] In particular, a base lid comprises a base plate and a peripheral wall extending from the periphery of the base plate. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0141] - 17 -

[0142] In particular, an inner side of a peripheral wall of a base lid configured to from a sealed connection with a housing of a device.

[0143] In particular, the inner side of a peripheral wall comprises internal threads corresponds to external threads formed on a second end of a housing.

[0144] Other methods of connecting the base lid to the housing are also possible, including but not limited to alternative fastening mechanisms such as snap-fit connections, magnetic closures, or clamping systems.

[0145] In particular, a device for manufacturing a casting mould further comprises a mounting element (integrally) formed in a base lid, e.g. a base plate of the base lid, wherein the mounting element is configured to hold a positive model within the interior space of the housing.

[0146] In particular, the mounting element is configured to fix a position of a positive model during a mould manufacturing process.

[0147] In particular, a mounting element comprises a flexible material.

[0148] In particular, a positive model comprises a gate structure which is configured to be (securely) attached to a mounting element.

[0149] In particular, the gate structure of the positive model is configured to provide a pathway through which a molten material (e.g., a moulding compound or a casting material) flows from the injection point (e.g. a sprue) into a cavity of a mould.

[0150] In particular, a device for manufacturing a casting mould further comprises a top lid, wherein the top lid is configured to create a sealed connection with a first end of the housing of the device.

[0151] In particular, a top lid comprises a top plate and a peripheral wall extending from the top plate. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0152] - 18 -

[0153] In particular, an inner side of the peripheral wall of the top lid comprises threads configured to engage with threads formed at the first end of the housing of the device.

[0154] In particular, a device for manufacturing a casting mould is configured to guide a moulding compound into the gate structure of the positive model that is fixed in place by the mounting element.

[0155] In particular, a moulding compound can be made from materials such as silicone rubber, gypsum, epoxy, or ceramic-based mixtures, depending on the application. These materials are chosen for their ability to capture fine details, dimensional stability, and suitability for the intended casting process, including metal, resin, or plaster casting.

[0156] Advantageously, the elastic deformation of the housing due to the slit and securing element simplifies the extraction process. This reduces the risk of damaging the hardened casting mould, especially for complex shapes with fine details or undercuts.

[0157] In addition, the ability to shake or turn the container with a secure top lid allows for better distribution of the moulding compound and effective air bubble removal, resulting in higher-quality moulds with fewer defects.

[0158] The flexible housing, combined with mechanically secured components, ensures easy disassembly and reusability. This reduces material waste and makes the device more cost-effective and sustainable for repeated use.

[0159] In particular, the housing functions as a spring mould container including a sealing mechanism that enables the housing to be opened and detached (separated) from the base lid. This design facilitates the easy removal of the casting mould without the need to invert or damage the shape.

[0160] The present invention further relates to a process for manufacturing a casting mould using a device as described above. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0161] - 19 -

[0162] In particular, the method comprises the steps of:

[0163] - providing a housing (e.g. a mould container) comprising an interior space, a slit extending along its surface, and a securing element (e.g. a flexible sealing element or a mechanical element);

[0164] - placing a positive model into the housing such that the positive model is positioned within the interior space;

[0165] - optionally, attaching a base lid with a positive model mounted (fixed) thereon to the housing (e.g. a second end of the housing)

[0166] - pouring a moulding compound into the housing to surround the positive model;

[0167] - optionally, attaching a top lid to the housing (e.g. to a first end of the housing) to enable secure shaking or turning of the housing, thereby removing air bubbles from undercuts or intricate areas of the positive model;

[0168] - allowing the moulding compound to harden for a predetermined time, forming a hardened mould around the positive model;

[0169] - optionally, removing the top lid and base lid from the housing after the moulding compound has hardened;

[0170] - deforming the housing elastically by utilizing the slit and securing element to increase its interior diameter; and

[0171] - extracting the hardened moulding compound, now forming the mould, from the housing.

[0172] The present invention further relaters to a mixing device and a method for a dust-free mixing of moulding materials.

[0173] A significant challenge in the production of casting moulds for investment casting is the handling of powdered moulding compounds, which are prone to generating dust during mixing. This dust release not only complicates the process but also poses health risks, particularly from substances like quartz dust, which is known for its harmful effects on the respiratory system when inhaled. The fine particles can linger in the air and are difficult to control, increasing the potential for contamination in the surrounding environment. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0174] - 20 - ln a domestic setting, this is especially concerning, as dust exposure can negatively impact air quality and health. Furthermore, in confined spaces, the dust can settle on surfaces, creating an ongoing cleaning challenge. These factors make traditional methods of mixing the moulding compound, which are prone to dust generation, inadequate and unsuitable for such applications where a dust-free process is essential for both safety and operational efficiency.

[0175] In order to address the above drawbacks of the conventional method, the present invention provide for an improved method for mixing moulding materials in a dust-free and clean condition.

[0176] In particular, the present invention further relates to a mixing device for mixing a moulding material with a liquid, e.g. water or a liquid containing water.

[0177] The mixing device comprises:

[0178] - a soluble pouch comprising a pre-packaged amount of moulding materials, preferably, the soluble pouch being configured to dissolve in a liquid, such as water;

[0179] - a flexible mixing vessel comprising an opening for receiving the water-soluble pouch, preferably the opening being configured to be closed; wherein the mixing vessel comprises a volume configured to enclose the water-soluble pouch and a predetermined amount of water to mixed with the moulding material within the pouch.

[0180] In particular, the opening of the mixing vessel can be closed using various mechanisms depending on its design and purpose. For example, the opening can be closed by a zipper seal, a clamp or clip closure, wire closures, elastic band, or heat sealing,

[0181] In particular, the mixing vessel further comprises an outlet for dispensing the moulding material mixed with the liquid.

[0182] In particular, the mixing vessel further comprises a closure cap (e.g. a screw cap) configured to seal the outlet. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0183] - 21 -

[0184] In particular, the mixing vessel further comprises one or more handles for ease of handling.

[0185] In particular, the mixing device further comprises a removable sieve (e.g. a lid with holes) that is configured to be coupled to the outlet of the mixing vessel, i.e. in place of the closure cap, to filter lumps or undissolved remnants of the pouch during dispensing.

[0186] In particular, the mixing device further comprises a measuring vessel for adding liquid to the pouch in a pre-determined ratio with the moulding materials.

[0187] In particular, the mixing device further comprises a means for shaking and kneading the mixing vessel to mix the moulding material and liquid into a homogeneous mixture.

[0188] In particular, the mixing device further comprises an addition mechanism for introducing emulsifiers such as soy lecithin or propylene glycol into the moulding material or the mixture of the moulding material to reduce viscosity and minimize air bubble formation.

[0189] In particle, the pouch comprises a water-soluble material, such as polyvinyl alcohol (PVA).

[0190] Some other examples of the water-soluble materials comprise Polyethylene Glycol (PEG), Gelatin, Carboxymethylcellulose (CMC) and Chitosan, derived from chitin and soluble in acidic solutions.

[0191] In particular, the present invention provides for a method for preventing dust release during the mixing of moulding materials.

[0192] In particular, the method uses a mixing device described above.

[0193] In particular, the method comprises the steps of: DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0194] - 22 -

[0195] - pre-packaging the moulding materials in liquid-soluble pouches, e.g. water-soluble pouches made of a material such as polyvinyl alcohol (PVA), the liquid-soluble pouches comprising predetermined portions of the moulding material;

[0196] - inserting a pre-packed pouch into a mixing vessel, preferably the mixing vessel comprising an opening to receive the pouch;

[0197] - adding a liquid into the mixing vessel for combining the moulding material with the liquid, e.g. water, preferably the mixing vessel further comprising one or more handles, and / or an outlet with a closure cap;

[0198] - optionally, adding liquid, e.g. water, in the appropriate proportion using a measuring vessel;

[0199] - sealing or closing the opening of the mixing vessel and allowing the pouch to dissolve in the liquid;

[0200] - shaking and kneading the mixing vessel to mix the moulding material and liquid until a homogeneous mixture is formed; and

[0201] - optionally, adding emulsifiers, such as soy lecithin or propylene glycol, to the mixture to reduce or prevent the increase in viscosity caused by the dissolved material of the pouch.

[0202] In particular, the mixing method helps prevent the release of dust into the environment and also minimizes the formation of air bubbles within the mixture.

[0203] In particular, the mixing vessel comprises a flexible material.

[0204] In particular, the mixing vessel further comprises a transparent section.

[0205] Advantageously, the homogeneity of the mixture can be visually and tactilely confirmed due to the flexible, partially transparent nature of the vessel.

[0206] It is schematically shown in

[0207] Fig. 1 a schematic block diagram of a casting system according to the present invention; DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0208] - 23 -

[0209] Fig. 2 a block diagram of exhaust gas treatment processes conducted within the casting system;

[0210] Fig. 3 a schematic cross-sectional view of a casting system;

[0211] Fig. 4 a detailed schematic cross-sectional view of a connecting unit;

[0212] Fig. 5 another schematic cross-sectional view of a casting system;

[0213] Fig. 6 a schematic cross-sectional view of a casting system comprising a mixing mechanism;

[0214] Fig. 7 another schematic cross-sectional views of a casting system comprising a mixing mechanism;

[0215] Fig. 8 a flowchart of a method for regeneration of a catalytic unit within a casting system ;

[0216] Fig. 9 a perspective schematic cross-sectional view of a device for manufacturing a casting mould;

[0217] Fig. 10 top and side views of the housing of a device for manufacturing a casting mould;

[0218] Fig. 11 a mixing device for dust-free mixing of a moulding material;

[0219] Fig. 12 a flowchart of a method for preventing dust release during the mixing of moulding materials;

[0220] Fig. 13 a flow chart of a method of manufacturing objects using the casting system;

[0221] Fig. 14 an exemplary picture of an object produced by a casting system according to the present invention;

[0222] Fig. 15 an exemplary picture of an object produced by a casting system according to the present invention;

[0223] Fig. 16 an exemplary picture of an object produced by a casting system according to the present invention; and

[0224] Fig. 17 a diagram illustrating temperature and pressure profiles of the components of the casting system during the execution of a method for manufacturing objects.

[0225] Fig. 1 shows a schematic block diagram of a casting system according to the present invention. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0226] - 24 -

[0227] The casting system 100 is configured to produce metallic objects 1000 (shown in Fig. 14-16).

[0228] The casting system 100 comprises a compact design and is configured to be used in household environments.

[0229] The casting system 100 is designed to effectively treat exhaust gases, minimizing the emission of harmful pollutants such as particulate matter, volatile organic compounds, and metallic fumes that are generated during the burn-out process and melting of metals into moulds.

[0230] The casting system 100 comprises a melting furnace 103, a burn-out furnace 104 and a catalytic unit 106.

[0231] The casting system 100 comprises a casing, e.g. an outer housing, which is configured to accommodate the melting furnace 103, the burn-out furnace 104, and the catalytic unit 106. Alternatively, the catalytic unit 106 is placed outside the casing of the casting system 100. For example, the catalytic unit 106 is coupled to the exterior of the main casing.

[0232] The molten materials are guided through a melt channel 105 into a casting mould 135, which is disposed in the burn-out furnace 104.

[0233] The casting system 100 comprises at least one pressure unit 107 configured to introduce fresh gas, e.g. air, into the casting system 100.

[0234] The casting system 100 further optionally comprises at least one suction unit 108 configured to evacuate the casting system 100 or remove excess gas from the casting system 100.

[0235] The catalytic unit 106 is configured to treat exhaust gases. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0236] - 25 -

[0237] The catalytic unit 106 is configured to receive the exhaust gases from the burn-out furnace 104 and convert harmful gases into harmless compounds.

[0238] The catalytic unit 106 further comprises a filter unit configured to capture fine particulates from the exhaust gas.

[0239] Fig. 2 shows a block diagram of exhaust gas treatment processes conducted within the casting system 100.

[0240] Exhaust gases with temperatures ranging from approximately 150°C to 750°C are directed into a heating unit. This step ensures the gases reach an optimal temperature, e.g. between 850°C to 1000°C, for subsequent filtration and catalytic reaction.

[0241] For example, the mass flow rate of the exhaust gas entering the heating unit ranges from 1 to 4 kg / h.

[0242] The heated exhaust gases are passed through a filter unit designed to capture fine particulate matter. This step removes solid particles that may originate from combustion residues or other process contaminants.

[0243] The filtered exhaust gases then pass through a catalytic element, where they undergo catalytic oxidation reactions. In this stage, harmful components such as carbon monoxide (CO), hydrocarbons, and other pollutants are converted into less harmful substances, such as carbon dioxide (CO2) and water (H2O).

[0244] Optionally, the converted exhaust gases are cooled in a cooling unit, reducing their temperature to a specified level (e.g., < 200 °C). During this cooling process, water vapor present in the gases condenses and is removed.

[0245] The cooled and treated exhaust gases (cleaned exhaust gasses) are directed through valve elements to monitoring sensors. These sensors measure the gas composition, water content (e.g., pH value), and unburned organic components. This ensures DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0246] - 26 - compliance with emission standards and verifies the effectiveness of the treatment process.

[0247] To remove water content from the cooled and treated exhaust gases, an evaporation step is further incorporated. At this step the gases pass through, for example, an evaporator or a water separation unit, to effectively remove excess moisture. The evaporation step can be conducted before the monitoring of the quality of the cleaned exhaust gas using the sensors.

[0248] In particular, the gases pass through units such as the evaporation or water separation unit to effectively remove excess moisture. The evaporation process can be carried out prior to monitoring the quality of the cleaned exhaust gas using the monitoring sensors.

[0249] In particular, the casting system further comprises various monitoring sensors to monitor the quality of the exhaust gases and unburned components.

[0250] For example, oxygen sensors (O2) measure the oxygen levels in the exhaust, while carbon monoxide (CO) and carbon dioxide (CO2) sensors detect incomplete combustion and combustion efficiency, respectively. Nitrogen oxide (NOx) sensors track pollutants formed at high temperatures, and hydrocarbon (HC) sensors detect unburned hydrocarbons.

[0251] For example, water content can be monitored using humidity sensors, which measure the moisture or vapor in the exhaust. To measure unburned organic components, total hydrocarbon (THC) sensors can be used, while particulate matter (PM) sensors detect fine soot and particles. Additionally, pH sensors can be used which monitor the acidity or alkalinity of the exhaust or condensed water, providing insights into unburned organic substances and chemical imbalances.

[0252] These sensors ensure that the exhaust treatment system operates efficiently and within regulatory limits. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0253] - 27 -

[0254] Fig. 3 shows a schematic cross-sectional view of a casting system 200, e.g. an investment casting system.

[0255] The casting system 200 is configured to manufacture metallic objects in household environments or residential spaces without generating harmful exhaust gasses.

[0256] The casting system 200 is configured to conduct gas treatments for removing hazardous pollutants (such as particulate matter, volatile organic compounds, and metal fumes) that can be generated during the casting process.

[0257] The casting system 200 comprises a compact main casing.

[0258] The main casing is dimensioned for portability and storage in confined residential spaces or compact industrial environments or spaces where exhaust emissions must be minimized.

[0259] For example, the main casing is configured to be placed on surfaces, such as desks, shelves, or countertops.

[0260] In particular, the main casing is sized within a range about 450 mm x 450 mm x 750 mm. Other dimensions within a comparable size range may be used as well.

[0261] The main casing is configured to enclose (i.e. it is constructed to accommodate) a melting furnace 203, a burn-out furnace 204 and a catalytic unit 206.

[0262] The main casing, for example, comprises a first chamber 201 , a second chamber 202 and a connecting unit 207 for fluidly connecting the first and second chambers 201 , 202.

[0263] In particular, the melting furnace 203 and the burn-out furnace 204 are configured to be positioned in the first chamber 201 . DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0264] - 28 - ln the first chamber 201 , the melting furnace 203 is positioned upstream of the burnout furnace 204.

[0265] For example, the melting furnace 203 comprises a melting container 211 (e.g. a crucible).

[0266] The melting container 211 comprises an outlet communicating with a melting channel 205.

[0267] The melting container 211 , for example, further comprises a closure element 212 configured to close the outlet of the melting container, thereby creating an enclosed melt chamber.

[0268] To fill the casting mould 235 with the melt, the outlet of the melting container 211 is configured to be opened at the bottom, allowing the molten material to flow downward in the direction of the gravity towards the casting mould 235.

[0269] For example, the melting container 211 further comprises a filtering medium (not shown) for retaining materials.

[0270] Raw materials can be placed before melting in the filtering medium, such as a mesh or sleeve made of temperature-resistant fabric.

[0271] During the melting process in the melting furnace 203, the molten material can exit through the openings of the fabric, while solid unwanted components, such as aluminium dross or slag, remain inside the fabric.

[0272] The filtering medium serves as a barrier that effectively separates molten material from potentially solid contaminants. This helps prevent damage to the melting container caused by the adherence of solid contaminants. Furthermore, it ensures that the unwanted elements do not reach the mould.

[0273] Advantageously, the use of the filtering medium prevents unwanted elements from reaching the casting mould and provides for a cleaner casting process. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0274] - 29 -

[0275] The catalytic unit 206 is configured to be positioned in the second chamber 202.

[0276] The connecting unit 207 comprises a gas channel 239 for guiding exhaust gases 219 from the first chamber 201 to the second chamber 202.

[0277] A sealing element 228 is provided to create a secure and sealed connection (airtight connection) between the connecting unit 207 and the first and second chambers 201 , 202. In this way, the first chamber 201 is hermetically connected to the second chamber 202, thereby maintaining an enclosed inner volume.

[0278] The burn-out furnace 204 comprises a casting mould 235.

[0279] The casting mould 235, for example, comprises a positive model 233 of an object to be manufactured by the casting system 200.

[0280] The positive model 233 is configured to be burned-out in the burn-out furnace 204.

[0281] The positive model 233 comprises a gate element 237 (or a gate structure) that is configured to receive molten materials (shown by a double arrow) through a melt channel 205 from the melting furnace 203.

[0282] The casting system 200, for example, the first chamber 201 and the second chamber 202, is configured to be operated under vacuum, overpressure or atmospheric conditions.

[0283] The casting system 200 further comprises a filter unit 223, e.g. a particulate filter, that is configured to capture and remove particulate matter from the exhaust gasses 219.

[0284] The particulate filter is configured to be positioned in the catalytic unit 206.

[0285] The catalytic unit 206 further comprises a catalyst material 218. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0286] - 30 - ln the second chamber 202, the catalyst material 218 is positioned downstream from the filter unit 223 along a flow direction of the exhaust gasses (shown by solid arrows).

[0287] For example, the catalyst material 218 comprises metals or mixed metal oxides dispersed or coated onto a porous substrate or a support material.

[0288] The porous substrate comprises porous ceramics, such as alumina (AI2O3), silica (SiO2), zeolites, or ceramic-based materials, and support material comprises metallic materials.

[0289] The metals or mixed metal oxides comprise platinum (Pt), rhodium (Rh), and palladium (Pd).

[0290] Advantageously the catalyst material is configured to convert harmful emissions like NOx, CO, and HCs into harmless substances (such as N2, CO2, and H2O).

[0291] The casting system 200 further comprises heating elements for heating the melting furnace 203, the burn-out furnace 204 and the catalytic unit 206.

[0292] The melting furnace 203 is configured to be heated and operate within a temperature range of 150°C to 1800°C.

[0293] In operation, the melting furnace 203 is configured to melt the material to be processed (e.g., aluminium, zinc, Inconel).

[0294] The temperature of the melting furnace is configured to be adjusted depending on the material to be molten. For example, for aluminium alloys a temperature of about 800°C is sufficient. Higher temperatures, up to around 1500°C, are necessary for Inconel, and up to about 1800°C for titanium.

[0295] Fig. 3 shows only one heating element 227 (e.g. a second heating element) that is positioned in the catalytic unit 206. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0296] - 31 -

[0297] The burn-out furnace 204 is configured to be heated up to 750°C.

[0298] The casting system 200 comprises a recirculation mechanism. The casting system 200 is configured to circulate cleaned exhaust gasses 245 back into the system.

[0299] After performing the burn-out process for burning the positive model 233, the mould 235 can be heated to the desired temperature for casting processes. This temperature depends on the casting material, the material of the mould, as well as the furnace characteristics, such as wall thicknesses, and gas flow paths within the casting system 200.

[0300] For example, for melting aluminium, temperatures of 200 to 500°C are usually employed, while higher temperatures may be advantageous for materials with higher melting points, such as Inconel or titanium.

[0301] During operation, the untreated exhaust gas stream 219 enters an inlet section 208 of the catalytic unit 206 through the connecting unit 207.

[0302] In the inlet section 208, the exhaust gas is heated to approximately 900°C by a (second) heating element 227, then passes through a particle filter of the filter unit 223 and the catalyst material 218.

[0303] The filter unit 223, for example, designed as a ceramic foam structure, which is directly heated by the (second) heating element 227 for promoting the combustion of deposited soot particles.

[0304] The catalyst material 218, for example, comprises a mixed metal oxide applied to a ceramic foam substrate. The catalyst material is configured to enable high operational temperatures, which is advantageous for this type of catalyst.

[0305] Other catalyst materials comprising fine-pored substrates may also be utilized in the catalytic unit 206. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0306] - 32 -

[0307] The casting system 200 further comprises pressure units 214 and 232 that are configured to supply the casting system 200 with fresh gas flows 215 and 230.

[0308] For example, a first pressure unit 214 is configured to supply a fresh gas flow 215 into the melting furnace 203.

[0309] A second pressure unit 232 is configured to supply a fresh gas flow 230 into the burnout furnace 204. The fresh gas flow 230, for example, comprises fresh air to facilitate or complete the burn-out process of the positive model 233 from the mould 235.

[0310] The flow rates of the first and second pressure units 214 and 232 can be independently adjusted as needed. The mass flow rates of the fresh gases range from 0 to 2 kg / h, depending on the operating conditions.

[0311] For example, in the casting system 200, e.g. within the casing, the fresh gas flow 215 enters from the upper section of the casing, while the fresh gas flow 230 enters from the lower section.

[0312] The provision of the fresh gas flow 215 via the second pressure unit 214 (such as a pressure pump) advantageously ensures that no moisture condenses around the melting furnace 203 by directing dry, fresh gas flow from top to bottom of the casing.

[0313] In particular, the casting system 200 further comprises at least one suction unit (e.g. a vacuum pump). For example, a first suction unit 210 is provided that is fluidly connected to the first chamber 201 , e.g. at close proximity of the melting furnace 203. This advantageously allows the melting and casting processes to occur under vacuum conditions.

[0314] The first chamber 201 of the casting system 200 and the second chamber 202 of the catalyst unit 206, i.e. the entire interior of the casting system 200 including the melting furnace 203, the burn-out furnace 204 and the catalytic unit 206, are configured to be evacuated by the first suction unit 210 (e.g. a vacuum pump). This allows the operation of the casting system 200 under vacuum conditions. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0315] - 33 -

[0316] The casting system 200 further may comprise a second suction unit (not shown) that is fluidly connected to the second chamber 202.

[0317] For example, the casting system 200 further comprises a filter element 217 that is configured to protect the first suction unit 210 from dust and / or contamination.

[0318] In particular, a plurality of valve elements is also provided that are configured to be connected to the pressure units and the suction units.

[0319] The provision of the valve elements before the suction unit and / or pressure units helps to regulate and control the flow of gases, ensuring that the casting system 200 operates efficiently. This also prevents unwanted backflow or contamination from the surrounding environment into the suction units (for example vacuum pumps) and the pressure units (e.g. a pressure pumps).

[0320] For example, Fig. 3 shows a (second) valve element 225. The valve element 225 functions as a discharge valve connecting the casting system and the external environment.

[0321] Alternatively, it is also possible that the suction unit is connected to the valve element 225.

[0322] Similarly, a first valve element, e.g. exhaust valve, (not shown) is configured to be connected to the first suction unit 210.

[0323] Optionally, a third valve element 231 (e.g. input valve) is provided that is configured to be connected to the second pressure unit 232.

[0324] During operation and after filtration and catalytic oxidation in the catalytic unit 206, cleaned exhaust gases 221 are configured to be guided through an outlet section 209 of the catalytic unit 206 and pass into a cooling unit 220. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0325] - 34 -

[0326] The cooling unit 220 is configured to reduce the temperature of the exhaust gasses, e.g. down to 200°C, prior entry into a second valve element 225

[0327] In the cooling unit 220 water 224 may partially condense from the cleaned exhaust gas 221.

[0328] For example, a significant portion of the water originates from the casting mould 235, which contains about 35% by weight of water (approximately 1 liter). Additional water is produced as a combustion byproduct during the burn-out process of the positive model 233. The condensed water can either be collected in a condensation tank or evaporated using an evaporation unit (not shown).

[0329] For example, the evaporation unit is configured to be mounted near the catalytic unit 206 to utilize its waste heat for water evaporation.

[0330] The evaporation unit is preferably inside of the main casing of the casting system.

[0331] The casting system 200 may further comprise a first sensor 242 configured to analyse the water composition, such as pH value and unburned organic components.

[0332] For example, a second sensor 243 may also be provided to measure the exhaust gas composition, including oxygen and carbon monoxide levels. Advantageously, this sensor helps to monitor and optionally regulate exhaust gas treatment.

[0333] After passing through the optional exhaust gas sensor (i.e. the second 243), part of the cleaned exhaust gas 246 can be released (discharged) into the environment, while another portion 245 is configured to be redirected into the first chamber 201 of the casting system via an actuator 244 to thereby perform exhaust gas recirculation. The gas recirculation advantageously enhances combustion efficiency.

[0334] The casting system 200 may further comprise insulation elements (not shown) for thermal insulation of the melting furnace 203, the burn-out furnace 204 and the catalytic unit 206. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0335] - 35 -

[0336] Fig. 4 shows a detailed cross-sectional schematic view of the connecting unit 207.

[0337] The connecting unit 207 is configured to guide the exhaust gasses 219 from the burnout furnace 204 to the catalytic unit 206. The untreated, hot exhaust gases 219 are configured to flow through the exhaust gas channel 239 of the connecting unit 207.

[0338] In particular, the connecting unit 207 comprises (or is made of) a thermal insulating material suitable to withstand high temperatures up 1200°C.

[0339] The connecting unit 207 is configured to protect walls of the first and second 201 , 202 as well as the sealing element 228 from high temperatures.

[0340] Optionally, a support element 240 is provided to mechanically stabilize the sealing element 228. Advantageously, the support element 240 is designed to prevent the sealing element 228 from displacement or being 'sucked in' due to pressure variations, such as overpressure or vacuum conditions, within the casting system 200.

[0341] Fig. 5 shows another schematic cross-sectional view of a casting system 300, e.g. an investment casting system.

[0342] The casting system 300 comprises components like the casting system 200. The casting system 300 however is not configured to recirculate the cleaned exhaust gas into the casting system 300.

[0343] The casting system 300 comprises a first chamber 301 fluidly communicating with a second chamber 302 through a connecting unit 307.

[0344] A sealing element 328 is provided for creating a sealed connection between the connecting unit 307 and the first and second chambers 301 , 302. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0345] - 36 -

[0346] The first chamber 301 accommodates a melting furnace 303 and a burn-out furnace 304. The molten materials are configured to be transferred into a casting mould 335 through a melt channel 305.

[0347] A melting container 311 comprising a stopper element 312 for closing an outlet of the melting container 311 is configured to be disposed in the melting furnace 303.

[0348] A fresh gas flow 315 from a first pressure unit 314 is configured to pass across the first chamber 301 (shown by arrows) and be transferred via a gas channel 339 of a connecting unit 307 into the catalytic unit 306 disposed in the second chamber 302.

[0349] Optionally, a further fresh gas flow is configured to be delivered into the first chamber 301 via a second pressure unit 332. In this example, a third valve element 331 (e.g. input valve) is provided after the second pressure unit 332.

[0350] In particular, a first heating element 316 is positioned in the melting furnace 303.

[0351] A second heating element 327, for example, is positioned in the catalytic unit 306 and a third heating element 329 is positioned in the burn-out furnace 304.

[0352] The burn-out furnace 304 may further comprise a fourth heating element 336 that is positioned close to the entry of the melt channel 305.

[0353] During operation, the untreated exhaust gas flows 319 are guided into an inlet section 308 of the catalytic unit 306, heated by the second heating element 327 and then passed through a particle filter of a filter unit 323 followed by the catalyst material 318.

[0354] During operation, the untreated exhaust gas is directed into an inlet section 308 of the catalytic unit 306. The gas is then heated by the second heating element 327 to a high temperature (e.g. up to 900°C).

[0355] After heating, the heated gas passes through a particle filter within a filter unit 323, where fine particulates are captured. Subsequently, the filtered exhaust gas flows DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0356] - 37 - through the catalyst material 318, where catalytic reactions take place to convert harmful pollutants into less harmful substances. This multi-stage process helps reduce emissions and improve the overall efficiency of the casting system.

[0357] The cleaned gas exits through an outlet section 309 of the catalytic unit 306 into a cooling unit 320. Exhaust gas and water contents 324 that are condensed are configured to pass through a second valve element 325 to an evaporation unit 322.

[0358] A cleaned exhaust gas 321 is configured to be discharged into environment.

[0359] Fig. 5 further shows a first insulation element 326 for thermal insulation of the burn-out furnace 304.

[0360] A second insulation element 334 is also provided for thermal insulation of the catalytic unit 306.

[0361] Fig. 6 shows a schematic cross-sectional view of a casting system 400, e.g. an investment casting system, comprising a mixing mechanism.

[0362] In particular, the casting system further comprises a mixing mechanism for mixing of additives into the molten material and for homogenizing the melt.

[0363] Advantageously, the mixing mechanism is further configured to improve the mixing of various additives, such as silicon carbide nanoparticles, to refine the grain structure and enhance the material properties.

[0364] In particular, the mixing mechanism comprises a stirring unit.

[0365] In this example, the casting system 400 further comprises a mixing mechanism for mixing of additives into the molten material and for homogenizing the melt.

[0366] The casting system 400 comprises similar components as described for the casting system 200 and 300. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0367] - 38 -

[0368] The mixing mechanism comprises a stirring unit 250 that is configured to be operably mounted to a melting furnace of the casting system 400.

[0369] The melting furnace, for example, is similar to the melting furnace 203, 303 as shown in Figs. 3 and 5.

[0370] The stirring unit 250 comprises a drive element 251 , e.g. a motor, a connecting element 252 configured to connect the drive element 251 to a mixing element 253.

[0371] The stirring unit 250 further comprises a stirring weight 254 attached to an end of the mixing element 253.

[0372] The stirring weight 254 is configured to contact a surface of molten casting materials 256 or to be immersed into the molten casting materials.

[0373] The stirring weight 254, for example, comprises ceramics or metals.

[0374] In particular, the mixing element 253 comprises a flexible material or a rigid material.

[0375] In particular, the mixing element 253, for example, comprises silicate, particularly calcium-magnesium-silicate, fiberglass or ceramic fibers.

[0376] For example, the mixing element comprises the fabric material used in the filtering medium described above.

[0377] Fig. 7 shows schematic cross-sectional views of a casting system 500, e.g. an investment casting system, comprising a mixing mechanism.

[0378] In this example, the stirring unit 250 further comprises a deflection element 255, which enables the driving element 251 to be mounted laterally and the length of the mixing element 253 i.e. , a flexible mixing element, to be automatically adjusted so that it can contact the surface of the melt within the melt container 211 , 311. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0379] - 39 -

[0380] This design allows the melt container 211 , 311 to be filled with irregularly shaped solid (unmelted) casting materials 257. This enables a higher fill level to be achieved within the melting container 211 , 311.

[0381] During the subsequent melting process, the stirring unit 250 is configured to automatically adjust the length of the mixing element 253, allowing it to sink into the molten materials 256. Freezing of the mixing element 253 after solidification does not present a problem.

[0382] In the left view of Fig. 7, the mixing element 253 is shown in its contracted state, and in the right view of Fig. 7, the mixing element 253 is shown in its expanded state.

[0383] The mixing element 253 is cost-effective and can be used as a disposable product.

[0384] Fig. 8 shows a flowchart of a method 700 for regeneration of the catalytic unit of the casting system 200, 300.

[0385] For example, the catalytic unit 206, 306 is configured to be cleaned by directing a reverse flow of gases, i.e. in an opposite direction of the exhaust gas flow, to remove contaminations from the filter unit 223, 323 and the catalyst material 218, 318.

[0386] The removed particles or contaminants are carried away by the reversed flow of gases introduced into the casting system 200, 300.

[0387] A continuous reverse gas flow through the casting system 200, 300 can be initiated 702 using a suction unit, e.g. the first suction unit 210, 310, and by opening a valve element, e.g. the valve element 225, 325, to ambient pressure creating a steady gas flow (e.g. airflow) in the reverse direction (i.e. opposite to the normal gas flow during the casting operation) through the casting system. The reverse gas flow removes contaminants from the catalytic unit 206, 306 and carries them towards the burn-out furnace 204, 304. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0388] - 40 -

[0389] Alternatively, a reverse gas flow, e.g. from the catalytic unit 206, 306 towards the burnout furnace 204, 304, is introduced 704 into the outlet section 209, 309 of the catalytic unit 206, 306 by means of a pressure unit (e.g. a pressure pump).

[0390] For example, one of the existing pressure units 214, 314 and 232, 332, which generate gas flows 215, 315 and 230, 330, can be repurposed for this task by using an appropriate switching mechanism. This ensures a consistent reverse flow to remove contaminants.

[0391] Yet another method to regenerate the catalytic unit includes generating 706 an intermittent reverse gas flow. This method combines evacuation and high-amplitude air influx to remove particles. First, the casting system 200, 300 (i.e. the first chamber and the second chamber) are evacuated using a vacuum pump. Once evacuated, a valve element, e.g. the valve element 225, 325 is opened, allowing ambient air to rush into the evacuated chambers of the catalytic system through the catalytic unit 206, 306. The resulting rapid differential pressure generates a strong airflow with high velocity and amplitude, effectively loosening and transporting embedded contaminants.

[0392] The contaminants removed by the reversed flow are guided 708 (carried) toward the burn-out furnace 204, 304.

[0393] If necessary, the contaminants are further removed 710 by another suction unit, e.g. the first suction unit 210, 310.

[0394] To ensure safe and efficient operation, a filter, such as the filter element 217, can be installed to capture remaining particles, protecting the first suction unit 210, 310 from contamination during the regeneration process.

[0395] Fig. 9 shows a perspective schematic cross-sectional view of a device 610 for manufacturing a casting mould 135, 235, 335.

[0396] The device 610 comprises a housing 609, a top lid 601 , and a base lid 608. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0397] - 41 -

[0398] The top and base lids 601 , 608 are configured to be connected to the housing 609 in a sealed manner.

[0399] The housing 609 is configured to define an interior space for enclosing a model 605 (e.g. a positive model) of an object to be produced by a casting process.

[0400] The housing 609 comprises a slit 603 extending between a first end 612 and a second end 613 of the housing 610.

[0401] Advantageously, the slit 603 provides flexibility to the housing 609, allowing its dimensions to be changed without causing any damage to the structure of the housing 609.

[0402] This flexibility allows the housing 609 to be expanded or contracted as required, making it easier to remove the hardened moulding component 602 from within the housing 609 while preserving the intended shape of the mould to be manufactured.

[0403] For example, a securing element 604 is provided to adjust the size of the slit 603, allowing it to be expanded, reduced, opened, or closed as needed.

[0404] Upon activating the securing element 604, the housing 609 expands and detaches from the hardened moulding compound 602, allowing the fabricated mould to be removed easily. This design minimizes the risk of damaging delicate edges or surfaces, ensuring the integrity and precision of the manufactured mould.

[0405] The base lid 608 comprises a mounting element 607 that is formed on a base plate of the base lid.

[0406] The mounting element 607 is configured to hold and fixe the position of the model within the housing 609. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0407] - 42 -

[0408] The model 605, for example, comprises a gate structure 606 configured to be connected to the mounting element 607. The gate structure 606 comprises a sprue for guiding the moulding material or moulding compound into the housing 609.

[0409] Fig. 10 shows top and side views of the housing 609 of the device 610.

[0410] In this example, the securing element 604 is shown in a closed / com pressed state for closing the housing 609 and in an open / stretched state for opening the housing 609 (see top views in Fig. 10).

[0411] In this example, the securing element 604 is illustrated in two distinct configurations: a closed or compressed state (as shown in the left top view in Fig. 10), which defines a first volume of the housing 609, and an open or stretched state (as shown in the right top view in Fig. 10), which allows the housing 609 to be expanded, defining a second, larger volume. This dual functionality ensures ease of operation and enables the easy removal of the mould from the housing 609.

[0412] For example, the securing element 604 includes a flexible sealing element fixed to the housing 609. The securing element is configured to be attached to the interior of the housing 609 and covering at least a portion of the total length of the slit 603 along a longitudinal direction.

[0413] Mechanical connections 611 , e.g. in the form of threads, that are created on the first end 612 and the second end 613 of the housing 609 are visible from the side view in Fig. 10, which shows the housing 609 in the open position.

[0414] For manufacturing the casting mould, the moulding material 602 (e.g. a mixed moulding compound) is poured into the housing 609, forming a mould container, to surround (and enclose) the positive model 605 (a replica of the object to be cast).

[0415] For added functionality, for example, the top lid 601 can be screwed onto the housing 609 to allow shaking or turning without spilling the moulding compound, which helps remove air bubbles from intricate parts or undercuts of the positive model. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0416] - 43 -

[0417] The moulding material 602 hardens in about 30-45 minutes. Once hardened, the top lid 601 and the base lid 608 of the housing 609 are detached, e.g. unscrewed.

[0418] Advantageously, the inclusion of a slit 603 and a flexible securing element 604 allow the housing 609 to be elastically deformed.

[0419] For example, the moulding material 602 can be easily removed from the housing 609 by pushing it out either upward or downward.

[0420] This deformation increases the internal diameter of the housing, facilitating the easy removal of the hardened moulding material, which now serves as a casting mould.

[0421] Additionally, the mechanical connections 611 , such as threads provide secure closure of the housing 609 and flexibility for attachment of the top and base lids 601 , 608.

[0422] Fig. 11 shows a mixing device 800 for dust-free mixing of a moulding material.

[0423] In this example, the moulding material comprises gypsum or a gypsum mixture.

[0424] To prevent dust release during the mixing of the moulding material, the moulding material 804 is pre-packaged in pouches 802.

[0425] For example, the water-soluble pouches are made of polyvinyl alcohol (PVA) and comprise the moulding material in suitable portions.

[0426] For mixing the moulding material with a liquid 814, a mixing vessel 810 is used.

[0427] The mixing vessel 810, for example, comprises a flexible and partly transparent material.

[0428] The mixing vessel 810 further comprises an opening 808, one or more handles 806, and an outlet configured to be closed with a closure cap 812, such as a screw cap. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0429] - 44 -

[0430] The closure cap 812 can be replaced by a removable sieve (e.g. a lid with holes) before pouring, which can trap lumps or undissolved remnants of the pouch.

[0431] The outlet of the mixing vessel 810 is used to pour the moulding mixture into a device, e.g. device 610, for manufacturing a casting mould.

[0432] Fig. 12 shows a flowchart of a method 900 for preventing dust release during the mixing of moulding materials.

[0433] In particular, the method 900 provides for a dust-free mixing of moulding materials with a liquid.

[0434] The liquid-soluble pouches 802 are packed 902 with a predetermined amount of a moulding material.

[0435] One pre-packed pouch 802 is inserted 904 into the opening 808, and the liquid, e.g. water, is then added 906.

[0436] The ratio of the moulding material to liquid is determined by the pre-packaged amount of the material and an appropriate amount of liquid.

[0437] The opening 808 of the mixing vessel 810 is sealed 908. Thereafter, the pouch 802 dissolves in the liquid.

[0438] The moulding material and liquid are mixed 910 by shaking and kneading until a homogeneous mixture is formed. This can be confirmed both haptically and visually as the mixing vessel 810 is flexible and partially transparent.

[0439] For example, in case of a pouch made of PVA mixed with water, the dissolved PVA increases the viscosity of the moulding material, which is disadvantageous for mould manufacturing and may promote the formation of air bubbles. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0440] - 45 -

[0441] This effect can be reduced or almost completely avoided by adding 912 emulsifiers, such as soy lecithin or propylene glycol, to the moulding material or the liquid.

[0442] For example, particularly practical is the addition of the emulsifiers to the pre-packaged pouches. Then normal tap water can be used for mixing without any further additives.

[0443] The present invention further provides for a system and a method for regeneration the catalytic unit 206, 306.

[0444] During operation, the filter unit 223, 323 and catalyst material 218, 318 may become clogged with dust particles (e.g., abrasion from thermal insulation materials) or soot.

[0445] To facilitate cleaning and regeneration of the catalytic unit, a system for regenerating the catalytic unit comprises:

[0446] - at least one suction unit (e.g. a vacuum pump) that is configured to create a reverse gas flow by evacuating the casting system;

[0447] - a valve arrangement operatively connected to the catalytic unit, the valve arrangement configured to open during operation of the at least one suction unit to allow a steady airflow in the reverse direction, thereby carrying contaminants away from the catalytic unit;

[0448] - a pressure unit (a pressure pump) configured to introduce pressurized air into the outlet of the catalytic unit to create a reverse gas flow; and

[0449] - wherein the reverse gas flow facilitates the removal of contaminants from the catalytic unit and associated components.

[0450] The present invention further relates to a method of casting (metallic) objects in household or domestic environments using the casting system according to the present invention.

[0451] In particular, the casting system comprises a processor configured to perform the method of casting objects. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0452] - 46 - ln particular, the method of casting objects can also be performed on a processor of a personal computer connected to the casting system according to the present invention.

[0453] In particular, the casting system comprises a non-transitory computer-readable medium configured to store program code which, when executed, is operative to cause a processor to perform a method of manufacturing objects using the casting system according to the present invention.

[0454] Fig 13. shows a flow chart of a method 1100 of manufacturing objects using the casting system 100 to 500 according to the present invention.

[0455] The method 1100 of casting comprising the steps of:

[0456] - optionally, curing 1102 the casting mould in the burn-out furnace, preferably also removing potential condensates;

[0457] - optionally, drying 1104 the casting mould, including the positive model, positioned in the burn-out furnace using the third and fourth heating elements, preferably at the same time preheating the catalytic unit using the second heating element to a first temperature required for catalytic processes;

[0458] - heating 1106 the burn-out furnace to a second temperature required for a subsequent burning step;

[0459] - burning out 1108 the positive model for a specific time while treating exhaust gas generated during burning process in the catalytic unit

[0460] - cooling down 1110 the casting mould to a third temperature lower than the second temperature while preheating the melting furnace;

[0461] - heating the melting furnace 1112 to a fourth temperature required for melting casting materials within the melting container;

[0462] - optionally, evacuating 1114 the casting system using the first suction unit, preferably the second and third valves are in a closed sate;

[0463] - activating the fourth heating element for heating 1116 an upper side of the burn-out furnace, thereby creating a temperature gradient along the longitudinal direction of the casting mould (e.g. in the direction of the gravity); DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0464] - 47 -

[0465] - casting 1118 the molten casting materials into the casting mould by opening the closure element of the melting container;

[0466] - optionally, pressurizing 1120 the first chamber by opening the third valve element;

[0467] - deactivating 1122 the fourth heating element after a given time period allowing for cooling off the casted object;

[0468] - optionally, monitoring operational parameters such as temperatures, pressures, currents;

[0469] - optionally, displaying the monitored parameters on a display.

[0470] Figs. 14, 15 and 16 show exemplary pictures of objects 1000 produced by the casting system 200, 300, 400, 500 according to the present invention.

[0471] Fig. 17 shows a diagram illustrating temperature and pressure profiles of the components of the casting system during the execution of a method for manufacturing objects according to the present invention.

[0472] The individual phases of the process as shown in Fig. 13 can be described as follows:

[0473] After starting the program, the multi-stage burn-out and casting process is automatically carried out by the casting system. The following diagram illustrates the temperature progression of the burnout chamber, melting container, and exhaust catalyst, as well as the pressure progression within the casting system.

[0474] The curing of the casting mould can be performed inside or outside of the burn-out furnace.

[0475] In particular, the curing is needed so the casting mould can reach its final strength.

[0476] Advantageously, condensation water can be removed via the one or more pressure units.

[0477] In particular, the airflow through the second chamber can range in between 0,5 kg / h to 2 kg / h, preferably 1 kg / h. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0478] - 48 -

[0479] Further, to prevent condensation of condensed water in the top part of the first chamber, the melting furnace can be preheated.

[0480] In particular, the melting furnace can be preheated to a temperature ranging between 100°C and 400°C, preferably 200°C.

[0481] The process further comprises the step of drying the casting mold to remove all excess water.

[0482] Advantageously, drying the casting mould increases its strength and resistance to high temperatures during the burn-out and casting steps.

[0483] In particular, the drying of the casting mould can be performed at temperatures ranging from 80°C to 200°C, preferably 120°C.

[0484] In particular, the drying process can take a timespan ranging from 1 hour to 6 hours.

[0485] The time required to dry the casting mould depends on the size and shape of the casting mould and the positive model inside.

[0486] Advantageously, the catalyst material inside the catalytic unit can be preheated, so that it reaches the working temperature when the burn-out process is initiated.

[0487] In particular, the desired working (operation) temperature of the catalytic material can range from 700°C to 1000°C, preferably between 800°C and 900°C.

[0488] To accelerate the preheating of the catalytic unit, the airflow through the second heating element, located upstream of the catalyst material inside the second chamber, created by the one or more pressure units, can be set to maximum capacity.

[0489] The airflow through the second chamber can range from 3 kg / h to 6 kg / h, preferably 4 kg / h. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0490] - 49 -

[0491] It is understood that the airflow through the first and second chambers may be adapted to the size and capacity of the casting system and can be significantly lower or higher than the above ranges, depending on the specific application.

[0492] Advantageously, the catalytic unit can also be used to clean exhaust gases that may already be produced during the drying of the casting mould.

[0493] The burn-out of the positive model includes a first step: the heat-up period of the burnout furnace, during which the furnace is heated to a temperature suitable for burning out all mould remnants of the positive model.

[0494] In particular, the burn-out temperature can range between 500°C and 900°C, preferably around 700°C.

[0495] The heating period of the burn-out furnace may take several hours to ensure uniform heating of the casting mould.

[0496] It is important to note that heating the casting mould too quickly can induce mechanical stresses within the mould.

[0497] During the heat-up period and the subsequent burn-out period, exhaust gases are carried by the airflow generated by one or more pressure units into the second chamber, where all harmful and odorous exhaust gases are filtered by the filter unit and then completely burned inside the catalytic unit.

[0498] The oxygen content within the casting system is controlled to facilitate a complete combustion of the exhaust gases.

[0499] The burn-out period can last between one and eight hours, depending on the size, volume, and complexity of the mould and positive model.

[0500] After the burn-out of the positive model, the mould is cooled down to a lower temperature before the casting process begins. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0501] - 50 -

[0502] The temperatures can vary over a wide range, from 150°C to 700°C, preferably between 200°C and 600°C, depending on the casting materials and the complexity of the model.

[0503] A higher mould temperature during casting can advantageously influence the flow characteristics of the molten casting materials, especially improving the quality of finer structures. On the other hand, a lower mould temperature can lead to a faster cooling time, also promoting a smaller grain size in the resulting material.

[0504] While the casting mould is being cooled down, the melting furnace can advantageously be preheated.

[0505] During the melting process in the melting furnace, the mixture of solid and molten casting materials can advantageously be continuously stirred using a stirring unit.

[0506] In particular, the mixing element and the stirring weight are configured to ensure that the weight element remains submerged in the molten casting material at all times.

[0507] Optionally, in some embodiments of the present invention, in an intermediate step, the first and second chamber can be evacuated, before the casting process begins.

[0508] In particular, pressure can range between 5 hPa and 100 hPa, preferably 5 hPa - 50 hPa.

[0509] In particular, the vacuum environment can have beneficial influence on the casting quality, as well as reduce the risk of oxidization of the casting material and enable the user to use casting materials that have a higher risk of oxidization. Further, risk of air bubbles in the solidified casting material can advantageously be reduced.

[0510] In the next step of the process, the closure element at the bottom of the melting container is opened and the molten casting materials are cast into the casting mould via the melt channel. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0511] - 51 -

[0512] In particular, the opening of the closure element can be actuated manually or automatically.

[0513] Advantageously, by using the fourth heating element (i.e., the top heating element) inside the burn-out furnace, a temperature gradient along the vertical axis of the casting mould can be created both before, during, and / or after the casting process, which helps ensure directed solidification of the melt from bottom to top,.

[0514] In particular, the optionally evacuated burn-out furnace can be depressurized or ventilated shortly after the casting process is completed.

[0515] As a final step, the casting system and the cast model are to be cooled down to allow the operator to safely remove them from the casting system.

[0516] In particular, throughout the process, a series of sensors can be used to monitor and / or control relevant process parameters, as well as to detect errors and other issues during operation at an early stage.

[0517] In particular, one measured and / or controlled variable comprises the temperature inside the melting furnace, the burn-out furnace, the catalytic unit, and / or the wall temperatures of the first and / or second chamber.

[0518] Additionally, a further measured and / or controlled variable comprises the current of the heating elements and / or other consumers, such as vacuum pumps or pressure units.

[0519] Another measured and / or controlled variable comprises the status of devices such as valves or the closure element of the melting container.

[0520] In particular, the method further includes processing the measured data, as well as analyzing and saving them using a processor and / or other suitable means. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0521] - 52 - ln particular, the method further comprises controlling all the processes of the casting system via the processor and appropriate control and input means. It can also include the ability to adapt and control the processes based on the measured and processed data.

[0522] The method can further include visualizing the data via a display screen or other suitable means to transmit information to a user.

[0523] In particular, the method can include controlling the casting system via the display and / or appropriate input means.

[0524] Advantageously, the method is configured to be conducted by a processor of a personal computer connected to the casting system.

[0525] The present invention further relates to the following aspects.

[0526] Aspect 1. A method for regenerating a catalytic unit in a casting system using an intermittent reverse gas flow, the method comprising the steps of:

[0527] - evacuating, using a first suction unit, the casting system including the catalytic unit to create a vacuum state within the casting system;

[0528] - opening a valve element to allow ambient air to enter the casting system, thereby creating a high-pressure differential and generating an intermittent reverse gas flow;

[0529] - allowing the intermittent reverse gas flow to pass through the catalytic unit, effectively loosening embedded particles and contaminants;

[0530] - transporting (or guiding) the loosened contaminants toward a burn-out furnace; and

[0531] - burning the contaminant in the burn-out furnaces and / or suctioning the contaminants using a suction unit to remove them from the casting system.

[0532] Aspect 2. A regeneration system for a catalytic unit in a casting system, the regeneration system comprising:

[0533] - preferably at least one suction unit configured to evacuate the casting system; DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0534] - 53 -

[0535] - at least one pressure unit configured to supply pressurized gas into the catalytic unit to create a reverse flow from the catalytic unit toward a burn-out furnace; and

[0536] - a valve arrangement operatively connected to the catalytic unit, the at least one suction unit, and the at least one pressure unit,

[0537] - the valve arrangement configured to open during operation of the at least one suction unit to allow a steady airflow into the casing system in the reverse direction, thereby carrying contaminants away from the catalytic unit, or

[0538] - the valve arrangement being configured to selectively allow ambient air to enter the evacuated casting system to create an intermittent high-pressure differential for removing embedded particles within the catalytic unit.

[0539] Aspect 3: The method according to aspect 1 or and the system according aspect 2, wherein the at least one pressure unit comprises a pressure pump used in the casting system, which is adapted to provide a continuous reverse gas flow into the catalytic unit.

[0540] Aspect 4: The method and / or the system according to aspect 3, wherein the valve arrangement includes at least one selectively operable valve configured to introduce ambient air into the evacuated casting system.

[0541] Aspect 5: The method and / or the system according to aspect 4, wherein a filter is positioned upstream of the suction unit to capture dislodged contaminants and prevent damage to the suction unit.

[0542] Aspect 6: The method and / or the system according to aspect 4 or 5, wherein the catalytic unit includes a particle filter and catalyst material configured to undergo reverse flow regeneration without structural damage.

[0543] Aspect 7: The method and / or the system according to one of aspects 4 to 6, wherein the high-pressure differential generated during the intermittent reverse flow achieves a peak airflow sufficient to loosen fine particulate contaminants embedded within the catalytic unit. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0544] - 54 -

[0545] Aspect 8: A device for manufacturing a casting mould, wherein the device comprises:

[0546] - a housing (e.g. a mould container) defining an interior space configured to enclose a positive model,

[0547] - the housing comprising a first end, a second end, and a slit extending along a longitudinal direction from the first end to the second end, and

[0548] - the slit being configured to facilitate the opening or access to the interior space of the housing.

[0549] Aspect 9: The device according to aspect 8, wherein the positive model is a model of an object to be manufactured by the casting process.

[0550] Aspect 10: The device according to aspect 8 or 9, wherein the housing exhibits localized flexibility facilitated by a slit extending along its surface.

[0551] Aspect 11 : The device according to one of aspects 8 to 10, wherein the slit is configured to create a gap or separation (e.g., between two halves of the housing) to enlarge the housing, thereby allowing for the easy removal of the manufactured casting mould.

[0552] Aspect 12: The device according to one of aspects 8 to 11 , wherein the device further comprises a securing element configured to hold the housing slit in either a first position (e.g., compressed or normal state), defining a first volume of the housing, or a second position (e.g., stretched or activated state), defining a second, larger volume of the housing.

[0553] Aspect 13: The device according to one of aspects 8 to 12, wherein the device further comprises a base lid, wherein the base lid configured to be attached to the housing, at a second end of the housing, through a mechanical connection (e.g. threaded connection).

[0554] Aspect 14: The device according to aspect 13, wherein the base lid comprises a base plate and a peripheral wall extending from the periphery of the base plate. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0555] - 55 -

[0556] Aspect 15: The device according to aspects 13 or 14, wherein an inner side of a peripheral wall of the base lid configured to from a sealed connection with a housing of a device, preferably the inner side of a peripheral wall comprising internal threads corresponds to external threads formed on a second end of a housing.

[0557] Aspect 16: The device according to one of aspects 8 to 15, wherein the device further comprises a mounting element (integrally) formed in a base lid, e.g. a base plate of the base lid, wherein the mounting element is configured to hold a positive model within the interior space of the housing.

[0558] Aspect 17: The device according to aspect 16, wherein the mounting element is configured to fix a position of a positive model during a mould manufacturing process, preferably the mounting element comprising a flexible material.

[0559] Aspect 18: The device according to one of aspects 8 to 17, wherein a positive model comprises a gate structure which is configured to be attached to a mounting element, preferably the gate structure of the positive model being configured to provide a pathway through which a molten material flows from the injection point (e.g. a sprue) into a cavity of a mould.

[0560] Aspect 19: The device according to one of aspects 8 to 18, wherein the device further comprises a top lid, wherein the top lid is configured to create a sealed connection with a first end of the housing of the device, preferably the top lid comprising a top plate and a peripheral wall extending from the top plate, wherein an inner side of the peripheral wall of the top lid comprises threads configured to engage with threads formed at the first end of the housing of the device.

[0561] Aspect 20: The device according to one of aspects 8 to 19, wherein a moulding compound can be made from materials such as silicone rubber, gypsum, epoxy, or ceramic-based mixtures, depending on the application. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0562] - 56 -

[0563] Aspect 21 : A method of manufacturing a casting mould using a device according to one of aspects 8 to 20.

[0564] Aspect 22: A method of manufacturing a casting mould comprising the steps of:

[0565] - providing a housing (e.g. a mould container) comprising an interior space, a slit extending along its surface, and a securing element (e.g. a flexible sealing element or a mechanical element);

[0566] - placing a positive model into the housing such that the positive model is positioned within the interior space;

[0567] - optionally, attaching a base lid with a positive model mounted (fixed) thereon to the housing (e.g. a second end of the housing)

[0568] - pouring a moulding compound into the housing to surround the positive model;

[0569] - optionally, attaching a top lid to the housing (e.g. to a first end of the housing) to enable secure shaking or turning of the housing, thereby removing air bubbles from undercuts or intricate areas of the positive model;

[0570] - allowing the moulding compound to harden for a predetermined time, forming a hardened mould around the positive model;

[0571] - optionally, removing the top lid and base lid from the housing after the moulding compound has hardened;

[0572] - deforming the housing elastically by utilizing the slit and securing element to increase its interior diameter; and

[0573] - extracting the hardened moulding compound, now forming the mould, from the housing.

[0574] Aspect 23: A mixing device and / or a method for a dust-free mixing of moulding materials.

[0575] Aspect 24: The mixing device according to aspect 23, wherein the mixing device comprises

[0576] - a soluble pouch comprising a pre-packaged amount of moulding materials, preferably, the soluble pouch being configured to dissolve in a liquid, such as water;

[0577] - a flexible mixing vessel comprising an opening for receiving the water-soluble pouch, preferably the opening being configured to be closed; DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0578] - 57 - wherein the mixing vessel comprises a volume configured to enclose the water-soluble pouch and a predetermined amount of water to mixed with the moulding material within the pouch.

[0579] Aspect 25: The mixing device according to aspects 23 or 24, wherein the opening of the mixing vessel can be closed using various mechanisms depending on its design and purpose. For example, the opening can be closed by a zipper seal, a clamp or clip closure, wire closures, elastic band, or heat sealing,

[0580] Aspect 26: The mixing device according to one of aspects 23 to 25, wherein the mixing vessel further comprises an outlet for dispensing the moulding material mixed with the liquid.

[0581] Aspect 27: The mixing device according to one of aspects 23 to 26, wherein the mixing vessel further comprises a closure cap (e.g. a screw cap) configured to seal the outlet.

[0582] Aspect 28: The mixing device according to one of aspects 23 to 27, wherein the mixing vessel further comprises one or more handles for ease of handling.

[0583] Aspect 29: The mixing device according to one of aspects 23 to 28, wherein the mixing device further comprises a removable sieve that is configured to be coupled to the outlet of the mixing vessel, i.e. in place of the closure cap, to filter lumps or undissolved remnants of the pouch during dispensing.

[0584] Aspect 30: The mixing device according to one of aspects 23 to 29, wherein the mixing device further comprises a measuring vessel for adding liquid to the pouch in a predetermined ratio with the moulding materials.

[0585] Aspect 31 : The mixing device according to one of aspects 23 to 30, wherein the mixing device further comprises a means for shaking and kneading the mixing vessel to mix the moulding material and liquid into a homogeneous mixture. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0586] - 58 -

[0587] Aspect 32: The mixing device according to one of aspects 23 to 31 , further comprising an addition mechanism for introducing emulsifiers such as soy lecithin or propylene glycol into the moulding material or the mixture of the moulding material to reduce viscosity and minimize air bubble formation.

[0588] Aspect 33: The mixing device according to one of aspects 23 to 32, wherein the pouch comprises a water-soluble material, such as polyvinyl alcohol (PVA).

[0589] Aspect 34: A method for preventing dust release during the mixing of moulding materials, preferably using a mixing device according to one of aspects 23 to 33.

[0590] Aspect 35: A method for preventing dust release during the mixing of moulding materials, wherein the method comprises the steps of:

[0591] - pre-packaging the moulding materials in liquid-soluble pouches, e.g. water-soluble pouches made of a material such as polyvinyl alcohol (PVA), the liquid-soluble pouches comprising predetermined portions of the moulding material;

[0592] - inserting a pre-packed pouch into a mixing vessel, preferably the mixing vessel comprising an opening to receive the pouch;

[0593] - adding a liquid into the mixing vessel for combining the moulding material with the liquid, e.g. water, preferably the mixing vessel further comprising one or more handles, and / or an outlet with a closure cap;

[0594] - optionally, adding liquid, e.g. water, in the appropriate proportion using a measuring vessel;

[0595] - sealing (closing) the opening of the mixing vessel and allowing the pouch to dissolve in the liquid;

[0596] - shaking and kneading the mixing vessel to mix the moulding material and liquid until a homogeneous mixture is formed; and

[0597] - optionally, adding emulsifiers, such as soy lecithin or propylene glycol, to the mixture to reduce or prevent the increase in viscosity caused by the dissolved material of the pouch.

[0598] Aspect 36: The method according to aspect 35, wherein the mixing vessel comprises a flexible material. DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0599] - 59 -

[0600] Aspect 37: The method according to aspect 35 or 36, In particular, the mixing vessel further comprises a transparent section.

[0601] DTS Ref.: 40252.AUM.P110PC

[0602] 08.12.2025

[0603] - 60 -

[0604] Reference Numerals

[0605] 100 Casting system

[0606] 103 Melting furnace

[0607] 104 Burn-out furnace

[0608] 105 Melt channel

[0609] 106 Catalytic unit

[0610] 107 At least one pressure unit

[0611] 108 At least one suction unit

[0612] 135 Casting mould

[0613] 200, 300 Casting system

[0614] 201 , 301 First chamber

[0615] 202, 302 Second chamber

[0616] 203, 303 Melting furnace

[0617] 204, 304 Burn-out furnace

[0618] 205, 305 Melt channel

[0619] 206, 306 Catalytic unit

[0620] 207, 307 Connecting unit

[0621] 208, 308 Inlet section of the catalytic unit

[0622] 209, 309 Outlet section of the catalytic unit

[0623] 210, 310 First suction unit

[0624] 211 , 311 Melting container

[0625] 212, 312 Closure element of the melting container

[0626] 313 First valve element

[0627] 214, 314 First pressure unit

[0628] 215, 315 First gas flow (fresh gas flow)

[0629] 316 First heating element

[0630] 217 Filter element

[0631] 218, 318 Catalyst material

[0632] 219, 319 Exhaust gas

[0633] 220, 320 Cooling unit DTS Ref.: 40252.AUM.P110PC 08.12.2025

[0634] - 61 -

[0635] 221 , 321 Cleaned exhaust gas

[0636] 322 Evaporation unit

[0637] 223, 323 Filter unit

[0638] 224, 324 Condensate I Condensed Water

[0639] 225, 325 Second valve element

[0640] 326 First insulation element

[0641] 227, 327 Second heating element

[0642] 228, 328 Sealing element

[0643] 329 Third heating element

[0644] 230, 330 Second gas flow (fresh gas flow)

[0645] 231 , 331 Third valve element

[0646] 232, 332 Second pressure unit

[0647] 233, 333 Positive model

[0648] 334 Second insulation element

[0649] 235, 335 Casting mould

[0650] 336 Fourth heating element

[0651] 237, 337 Gate element

[0652] 338 Melt

[0653] 239, 339 Gas channel of the connecting unit

[0654] 240 Support element

[0655] 242 First sensor

[0656] 243 Second sensor

[0657] 244 Actuator

[0658] 245 Circulated cleaned gas

[0659] 246 Discharge gas

[0660] 250 Stirring unit

[0661] 251 Drive element

[0662] 252 Connecting element

[0663] 253 Mixing element

[0664] 254 Stirring weight

[0665] 255 Deflection element

[0666] 256 Molten casting materials

[0667] 257 Solid casting materials DTS Ref.: 40252.AUM.P110PC

[0668] 08.12.2025

[0669] - 62 -

[0670] 400, 500 Casting system

[0671] 601 Top lid

[0672] 602 Moulding material

[0673] 603 Slit

[0674] 604 Securing element

[0675] 605 Model

[0676] 606 Gate structure

[0677] 607 Mounting element

[0678] 608 Base lid

[0679] 609 Housing

[0680] 610 Device for manufacturing a casting mould

[0681] 611 Mechanical connection

[0682] 612 First end

[0683] 613 Second end

[0684] 700 Method

[0685] 702 Method step

[0686] 704 Method step

[0687] 706 Method step

[0688] 708 Method step

[0689] 710 Method step

[0690] 800 Mixing device

[0691] 802 Liquid-soluble pouch

[0692] 804 Moulding materials

[0693] 806 One or more handles

[0694] 808 Opening

[0695] 810 Mixing vessel

[0696] 812 Closure cap

[0697] 814 Liquid DTS Ref.: 40252.AUM.P110PC

[0698] 08.12.2025

[0699] - 63 -

[0700] 900 Method

[0701] 902 Method step

[0702] 904 Method step

[0703] 906 Method step

[0704] 908 Method step

[0705] 910 Method step

[0706] 912 Method step

[0707] 1000 Objects

[0708] 1100 Method

[0709] 1102 Method step

[0710] 1104 Method step

[0711] 1106 Method step

[0712] 1108 Method step

[0713] 1110 Method step

[0714] 1112 Method step

[0715] 1114 Method step

[0716] 1116 Method step

[0717] 1118 Method step

[0718] 1120 Method step

[0719] 1122 Method step

Claims

DTS Ref.: 40252.AUM.P110.PC 08.12.2025- 64 -Claims1. A casting system (100, 200, 300, 400, 500), in particular an investment casting system, for manufacturing objects in confined spaces, the casting system (100, 200, 300, 400, 500) comprising:- a main casing, and- a catalytic unit (206, 306), wherein the catalytic unit (206, 306) is configured to be housed within the main casing or attached to the main casing, wherein the catalytic unit (206, 306) is configured to treat exhaust gasses (219, 319) by removing harmful components generated during operation, and wherein the main casing comprises dimensions suitable for portability and storage in confined spaces.

2. The casting system (100, 200, 300, 400, 500) according to claim 1 , characterized in that the casting system (100, 200, 300, 400, 500) further comprises- a melting furnace (103, 203, 303) configured to melt metals, and- a burn-out furnace (104, 204, 304) configured to heat a casting mould (135, 235, 335) for removing a positive model (233, 333) disposed in the casting mould (135, 235, 335), wherein the main casing is further configured to house the melting furnace unit (103, 203, 303) and the burn-out furnace (104, 204, 304), preferably the melting furnace (103, 203, 303) is positioned upstream from the burn-out furnace (104, 204, 304).

3. The casting system (100, 200, 300, 400, 500) according to claim 1 or claim 2, characterized in that the main casing comprises a first chamber (201 , 301 ), a second chamber (202, 302) and a connecting unit (207, 307) for fluidly connecting the first and second chambers (202, 302), wherein the second chamber (201 , 301 ) is configured to enclose the catalytic unit (206, 306),DTS Ref.: 40252.AUM.P110.PC 08.12.2025- 65 - wherein the first chamber (202, 302) is configured to enclose a melting furnace (103, 203, 303) and a burn-out furnace (104, 204, 304) of the casting system (100, 200, 300, 400, 500), and wherein the connecting unit (207, 307) comprises a gas channel for transferring gasses between the first and second chambers (202, 302) in a sealed manner.

4. The casting system (100, 200, 300, 400, 500) according to any one of the preceding claims, characterized in that the casting system (100, 200, 300, 400, 500) further comprises at least one pressure unit (107) configured to introduce fresh gas, preferably air, into the casting system (100, 200, 300, 400, 500), preferably a first chamber (201 , 301 ), and preferably, the at least one pressure unit (107) being configured to be connected to a first chamber (201 , 301 ) of the casting system (100, 200, 300, 400, 500).

5. The casting system (100, 200, 300, 400, 500) according to any one of the preceding claims, characterized in that the casting system (100, 200, 300, 400, 500) further comprises at least one suction unit (108) configured to evacuate the casting system (100, 200, 300, 400, 500), preferably a first chamber (201 , 301 ), the at least one pressure unit (107) is configured to be connected to a first chamber (201 , 301 ) of the casting system (100, 200, 300, 400, 500), preferably the at least one pressure unit (107) comprising a first pressure unit (214, 314) configured to deliver fresh gas from a side of the first chamber (201 , 301 ) located toward the upper end along the longitudinal direction, and a second pressure unit (232, 332) configured to deliver fresh gas from a side of the first chamber (201 , 301 ) located toward the lower end along the longitudinal direction.

6. The casting system according to claim 4 or 5, characterized in thatDTS Ref.: 40252.AUM.P110.PC 08.12.2025- 66 - the casting system further comprise valve elements configured control the flow of gases into or out of the casting system (100, 200, 300, 400, 500), wherein the valve elements are configured to be connected to at least one suction unit (108) and / or at least one pressure unit (107).

7. The casting system (100, 200, 300, 400, 500) according to any one of the preceding claims, characterized in that the casting system (100, 200, 300, 400, 500) further comprises heating elements for heating the catalytic unit (206, 306), a melting furnace (103, 203, 303) and a burn-out furnace (104, 204, 304) of the casting system (100, 200, 300, 400, 500), preferably the melting furnace (103, 203, 303) comprises a first heating element (216, 316), and / or the catalytic unit (206, 306) comprises a second heating element (227, 327), and / or the burn-out furnace (104, 204, 304) comprises a third heating element (329) positioned on a lower side of the casting mould (135, 235, 335) and a fourth heating element (236, 336) positioned on an upper side of the casting mould (135, 235, 335).

8. The casting system (100, 200, 300, 400, 500) according to any one of the preceding claims, characterized in that the casting system (100, 200, 300, 400, 500) further comprises a mixing mechanism configured to homogenise casting materials and / or incorporate various additives in a melting container (211 , 311 ) of a furnace of the casting system (100, 200, 300, 400, 500).

9. The casting system (100, 200, 300, 400, 500) according to any one of the preceding claims, characterized in that the catalytic unit (206, 306) further comprises a catalyst material (218, 318), wherein the catalyst material (218, 318) comprises metals or mixed metal oxides dispersed onto a porous substrate, and / orDTS Ref.: 40252.AUM.P110.PC 08.12.2025- 67 - the catalytic unit (206, 306) further comprises a filter unit (223, 323) configured to capture particulate matter from the exhaust gas (219, 319).

10. The casting system (100, 200, 300, 400, 500) according to any one of the preceding claims, characterized in that the casting system (100, 200, 300, 400, 500) further comprises an evaporation unit (322) configured to remove excess moisture from the treated exhaust gas (221 , 321 ), wherein the evaporation unit (322) is configured to be attached to the exterior of the main casing.

11. The casting system (100, 200, 300, 400, 500) according to any one of the preceding claims, characterized in that the casting system (100, 200, 300, 400, 500) further comprises a filtering medium configured to be positioned in a melting container (211 , 311 ), wherein the filtering medium, preferably a mesh comprising temperature- resistant fabric, is further configured to retain solid casting materials (257) and filter out solid contaminants from the molten casting materials (256) during operation of the casting system (100, 200, 300, 400, 500).

12. The casting system (100, 200, 300, 400, 500) according to any one of the preceding claims, characterized in that the catalytic unit (206, 306) is configured to be regenerated by a reverse gas flow from the catalytic unit (206, 306) toward a burn-out furnace (104, 204, 304), wherein the reverse gas flow is configured to be created:- by activating at least one suction unit (108) and by simultaneously opening a second valve element (225, 325) to environment to thereby create a continuous reverse gas flow; orDTS Ref.: 40252.AUM.P110.PC 08.12.2025- 68 -- by introducing a pressurized gas flow into an outlet of a catalytic unit (206, 306) using a pressure unit (107) to thereby create a continuous reverse gas flow from; or- by generating an intermittent reverse gas flow through evacuating, using at least one suction unit (108), the casting system (100, 200, 300, 400, 500); thereafter, opening a second valve element (225, 325) to allow ambient air to enter the evacuated casting system (100, 200, 300, 400, 500), thereby creating a high-pressure differential;13. The casting system (100, 200, 300, 400, 500) according to any one of the preceding claims, characterized in that the casting system (100, 200, 300, 400, 500) is configured to recirculate the treated exhaust gasses (221 , 321 ) into the casting system (100, 200, 300, 400, 500), and / or the casting system (100, 200, 300, 400, 500) further comprises a computing device configured to control the operation of the casting system (100, 200, 300, 400, 500).

14. A method of manufacturing objects using a casting system (100, 200, 300, 400, 500) according to any one of the preceding claims, wherein the method comprises the steps of: optionally, curing the casting mould (135, 235, 335) in the burn-out furnace (104, 204, 304), preferably also removing potential condensates; optionally, drying the casting mould (135, 235, 335) using the third and / or fourth heating elements (336), wherein the casting mould (135, 235, 335) comprises a positive model (233, 333) and is positioned in the burn-out furnace (104, 204, 304), and more optionally, at the same time preheating the catalytic unit (206, 306) using the second heating element (227, 327) to a first temperature required for catalytic processed; heating the burn-out furnace (104, 204, 304) to a second temperature required for a subsequent burning step;DTS Ref.: 40252.AUM.P110.PC 08.12.2025- 69 - burning out a positive model (233, 333) for a specific time while treating exhaust gas (219, 319) generated during burning process in the catalytic unit (206, 306) cooling down the casting mould (135, 235, 335) to a third temperature lower than the second temperature while preheating the melting furnace (103, 203, 303); heating the melting furnace (103, 203, 303) to a fourth temperature required for melting casting materials within the melting container (211 , 311 ); optionally, evacuating the casting system (100, 200, 300, 400, 500), preferably the second and third valve elements (225, 325, 231 , 331 ) are in a closed state; activating the fourth heating element (236, 336) for heating an upper side of the burn-out furnace (104, 204, 304), thereby creating a temperature gradient along the longitudinal direction of the casting mould (135, 235, 335); casting the molten casting materials (256) into the casting mould (135, 235, 335) by opening the closure element of the melting container (211 , 311 ); optionally, pressurizing the first chamber (201 , 301 ) by opening the third valve element (231 , 331 ); deactivating the fourth heating element (236, 336) after a given period of time allowing for cooling off the casted object (1000); and optionally, monitoring operational parameters such as temperatures, pressures, currents.

15. A non-transitory computer-readable medium configured to store program code which, when executed, is operative to cause a processor to perform the method manufacturing objects according to claim 14, in particular, using the casting system (100, 200, 300, 400, 500) according to any one of claims 1 to 13.

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