Flexible Mold for High Definition Ceramic Core
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Solution Overview
Problem
Current investment casting methods for producing ceramic cores are limited by the time-consuming process of creating rigid metal molds, which restricts flexibility and increases production costs, and the resolution of 3D printed ceramic cores is not sufficient for intricate geometries.
Innovation Solution
A method involving 3D printing of a consumable wax master tool with negative surface geometry to produce a flexible mold, allowing for quick curing and removal, followed by casting a ceramic core using a ceramic slurry within the flexible mold, which can be easily removed and processed for investment casting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional rigid metal molds are used for casting ceramic cores, then manufacturing precision can be maintained, but production time increases and flexibility decreases
Solution Approach 1:
The patent changes the physical state and properties of mold materials by using rapidly curing flexible mold materials that transition from liquid to solid state quickly, enabling fast production cycles while maintaining the ability to produce precise ceramic core geometries through controlled material parameter changes during the molding process
Solution Approach 2:
The patent employs disposable flexible molds that are used for a single casting cycle and then discarded, eliminating the need for durable metal tooling while maintaining manufacturing precision. The molds are inexpensive enough to be single-use items that enable rapid production without requiring long-term durability
2Manufacturing precision
If traditional metal master tooling is used, then manufacturing precision is maintained, but device complexity and cost increase
Solution Approach 1:
The patent uses simple master patterns or 3D printed models as templates to create flexible molds through copying processes, rather than requiring complex metal tooling. The mold cavity is formed by copying the geometry of a simple master object, which dramatically reduces device complexity while maintaining the precision needed for intricate ceramic core geometries
Solution Approach 2:
The patent changes the material parameters of the mold from rigid metal to flexible curable materials, which fundamentally simplifies the tooling system. This parameter change allows the mold to be created through simpler processes like pouring or injection into a master pattern, eliminating complex machining and assembly operations required for metal tooling
3Productivity
If flexible mold materials are used, then productivity increases, but manufacturing precision may be compromised
Solution Approach 1:
The patent carefully controls the material parameters of the flexible mold, specifically selecting materials with appropriate viscosity and curing characteristics that allow rapid setting while maintaining surface fidelity. The material parameters are optimized to ensure the flexible mold can capture fine geometric details during the quick molding process before curing completes
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 significantly reduces production time and costs by enabling the creation of ceramic cores with intricate geometries and advanced features, such as those found in turbine blades or vanes, while eliminating the need for traditional metal master tooling.
Implementation Method 1
The flexible mold material is then allowed to cure
Implementation Method 2
removing the cured ceramic core from the flexible mold once the ceramic core solidifies
Data Source
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AI summary
A method for producing a flexible mold for casting a ceramic core, the ceramic core used for an investment casting, is presented. The method includes forming a consumable master tool by 3D-printing, producing the flexible mold from the master tool, allowing the flexible mold to cure, and removing the consumable master tool. The master tool includes a negative surface geometry representative of the flexible mold to be produced.