Additive Layered Casting Mold for Complex Geometries
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Solution Overview
Problem
Existing 3D printing technologies are limited by their inability to efficiently produce complex geometries with high precision and cost-effectiveness, particularly in investment casting methods which are time-consuming and expensive.
Innovation Solution
A method employing additive layered manufacturing principles, where a 3D object is created by superimposing mold layers with chemically dissolvable pattern materials and temporary filling jackets, using induction heating to melt and fill the mold with metal or ceramic powders, allowing for multi-level metal pouring and precise geometric control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional investment casting methods are used to achieve high dimensional precision, then manufacturing precision is improved, but production time increases and cost increases
Solution Approach 1:
The mold is divided into multiple layers that can be independently manufactured and then assembled. Each layer is created separately using 3D printing technology, allowing parallel production of multiple layers simultaneously, which significantly reduces overall production time while maintaining high dimensional precision through controlled layer-by-layer construction
Solution Approach 2:
Pattern materials are pre-placed within the mold layers before the casting process. These removable pattern materials are positioned in advance to define the geometry of the final casting, allowing the mold structure to be prepared beforehand and reducing the time required during actual casting operations
2Manufacturing precision
If traditional investment casting methods are used to achieve high dimensional precision, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The mold is divided into multiple layers that can be independently manufactured and then assembled. Each layer is created separately using 3D printing technology, allowing parallel production of multiple layers simultaneously, which significantly reduces overall production time while maintaining high dimensional precision through controlled layer-by-layer construction
Solution Approach 2:
Removable pattern materials are used that can be easily removed after casting and are relatively inexpensive. These patterns serve their purpose during the casting process and are then discarded, eliminating the need for expensive, complex, and time-consuming mold preparation and cleanup operations associated with traditional investment casting
3Adaptability or versatility
If additive layered manufacturing is used to create complex geometries, then versatility is improved, but manufacturing precision may deteriorate
Solution Approach 1:
The mold is divided into multiple layers that can be independently manufactured and then assembled. Each layer is created separately using 3D printing technology, allowing parallel production of multiple layers simultaneously, which significantly reduces overall production time while maintaining high dimensional precision through controlled layer-by-layer construction
Solution Approach 2:
The process parameters such as layer thickness, printing speed, and material properties are optimized to achieve the desired balance between geometric complexity and dimensional precision. By carefully controlling these parameters, the additive manufacturing process can produce complex geometries while maintaining acceptable precision levels
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in a casting method that achieves high precision and versatility while being quicker and less expensive than traditional investment casting, capable of handling complex geometries with improved safety and accuracy.
Implementation Method 1
heating the object material by means of the induction heating means, until the object material melts
Data Source
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AI summary
Method for manufacturing an element of a plurality of casting mold elements assemblable to a 3-dimensional object casting mold, comprising: superimposing a plurality of mold layers, wherein each mold layer is made as follows: a) depositing casting pattern material inside at least one casting pattern material filling area determined by a digital model of the casting pattern, b) depositing temporary filling jacket material for making a boundary for at least one mold material filling area around the at least one casting pattern material filling area, c) filling the at least one mold material filling area with a casting mold material, d) removing the temporary filling jackets, e) filling the voids left be the removed jackets with the mold material and f) finishing the upper surface of the layer; and removing the casting pattern material.