Chill Casting Mold with 3D Printed Insert for Complex Geometries
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Solution Overview
Problem
Existing mold manufacturing for permanent mold casting is complex and costly, especially for components with diverse geometries, as different molds are required for each geometry, limiting efficiency and cost-effectiveness.
Innovation Solution
A casting mold comprising a permanent mold and an insert, where the insert shapes part of the component's outer contour, allowing for flexible production of components with complex geometries using 3D printing and reusable molds, enabling cost-effective and efficient manufacturing of components with varying geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If different molds are used for components with varying geometries, then manufacturing precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The mold is divided into two functional parts: a permanent mold body that provides structural support and a reusable cavity, and a separate insert that defines the specific geometry of the component. This segmentation allows the insert to be changed for different geometries while keeping the expensive mold body constant, thereby maintaining manufacturing precision across different components without increasing overall mold complexity.
Solution Approach 2:
The mold body is designed as a universal component that can accommodate multiple different inserts for casting components with various geometries. This multi-functionality allows a single mold body to serve multiple purposes, reducing the need for multiple specialized molds while maintaining the precision required for each specific component geometry.
2Manufacturing precision
If different molds are manufactured for each component geometry, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
By segmenting the mold into a permanent mold body and a separate insert, the manufacturing cost is distributed such that only the insert needs to be manufactured for each specific geometry, while the expensive mold body is reused. This significantly reduces the per-component manufacturing cost while maintaining precision through the dedicated insert design.
Solution Approach 2:
Instead of manufacturing a complete new mold for each component geometry, only the insert (which is the geometry-defining part) is manufactured as a copy or adaptation for each specific component. The expensive mold body serves as a reusable template, reducing overall manufacturing costs while maintaining the precision of each copied geometry.
3Ease of manufacture
If a simple mold geometry is used, then ease of manufacture is improved, but adaptability to different component geometries deteriorates
Solution Approach 1:
The mold is segmented into a simple, easy-to-manufacture mold body and a separate insert that provides the geometric adaptability. The mold body can be manufactured with simple geometry for ease of production, while the insert is customized for each specific component geometry, thereby maintaining both manufacturing simplicity and geometric adaptability.
Solution Approach 2:
The insert acts as an intermediary element between the simple mold body and the complex component geometries. It mediates the interaction by providing the necessary geometric complexity while allowing the mold body to remain simple and easy to manufacture. The insert is the intermediary that enables adaptability without complicating the main mold structure.
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
The solution allows for the simple and cost-effective production of molds and components with complex geometries, enabling flexible adaptation to different geometries and reducing production costs by using 3D printed inserts and reusable molds, making it suitable for small series production with high flexibility.
Implementation Method 1
The insert determines the shape of part of the outer contour of the component to be cast
Implementation Method 2
The insert and a portion of the mold body together define the outer contour of a component to be cast using the mold
Data Source
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AI summary
Mold for die casting, comprising: a mold (2), and an insert (32) which is arranged within the mold (2), wherein the insert (32) together with a part of the mold (2) shapes an outer contour of a component to be cast.