Flexible Tooling Liner for Ceramic Core Casting

Solution Overview

Problem

Current investment casting methods require time-consuming and costly machining of master tools for producing flexible tooling liners, which limits the speed and flexibility in producing ceramic cores for complex geometries like gas turbine components.

Innovation Solution

A method is introduced to produce flexible tooling liners by encapsulating a 3D reference object representative of the ceramic core in a liquid flexible tooling material, allowing it to cure, and then separating the cured tooling liner, which can be used to cast ceramic cores with controlled thickness for contoured geometries.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a master tool is machined from soft metal to define the geometry of the flexible tooling liner, then the manufacturing precision of the ceramic core is improved, but the production time and cost increase significantly

Engineering Contradiction:

Improveceramic core geometry precisionVSAvoidmaster tool machining time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent uses a 3D reference object (digital or physical) to create a mold that replicates the desired ceramic core geometry. Instead of machining a master tool, the reference object is used to form a mold through injection or casting processes, significantly reducing production time while maintaining geometric accuracy.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces the mechanical machining process with a 3D printing or injection molding process. The 3D reference object is processed through additive manufacturing or mold injection to create the flexible tooling liner directly, eliminating the need for time-consuming mechanical machining of master tools.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If a master tool is machined from soft metal to define the geometry of the flexible tooling liner, then the manufacturing precision of the ceramic core is improved, but the cost of production increases

Engineering Contradiction:

Improveceramic core geometry precisionVSAvoidproduction cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent uses a 3D reference object (digital or physical) to create a mold that replicates the desired ceramic core geometry. Instead of machining a master tool, the reference object is used to form a mold through injection or casting processes, significantly reducing production time while maintaining geometric accuracy.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces the mechanical machining process with a 3D printing or injection molding process. The 3D reference object is processed through additive manufacturing or mold injection to create the flexible tooling liner directly, eliminating the need for time-consuming mechanical machining of master tools.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If the master tool profile is altered to accommodate different ceramic core geometries, then the adaptability of the tooling system is improved, but the difficulty to alter the profile increases

Engineering Contradiction:

Improvetooling profile adaptabilityVSAvoidmaster tool alteration complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent employs a flexible tooling liner material that can be dynamically adjusted and reconfigured. The flexible nature of the material allows for easy modification of tooling profiles to accommodate different ceramic core geometries without requiring complex retooling or remachining operations.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent changes the physical state or properties of the tooling material to enable flexibility and adaptability. By using a flexible material that can be molded and re-molded, the system can easily adjust to different geometries by changing the molding parameters rather than altering the tooling structure itself.

Inventive Principle:

Principle #35Parameter changes

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 method significantly reduces the time and cost associated with producing flexible tooling liners, enables faster production of ceramic cores with complex geometries, and allows for easier alteration of tooling profiles, enhancing the efficiency of investment casting processes.

Implementation Method 1

allowing the liquid tooling material to cure

Methodology Applied

Scientific EffectCuring: Phase Change

Data Source

PatentUS12330210B2Method for producing flexible tooling for casting a ceramic core

Publication Date: 2025.06.17 SIEMENS ENERGY GLOBAL GMBH & CO KG

AI summary

A method for producing a flexible tooling liner for casting a ceramic core is presented. The method includes the steps of producing a three-dimensional (3D) reference object representative of a ceramic core to be cast, disposing the reference object into a containment vessel configured to receive a liquid flexible tooling material, filling the containment vessel with the liquid tooling material so that the reference object is encapsulated by the liquid tooling material on the surface whose topography is intended to be imparted, allowing the liquid tooling material to cure, and separating the cured flexible tooling along a parting surface into opposing portions and removing the reference the reference object.