Additive Manufactured Metal Shell Box with Lattice Back

Solution Overview

Problem

Existing core, mold, and pattern boxes made from materials like wood and epoxy have limited useful lives, and metal boxes are heavy and costly, necessitating the development of more effective and economical structures and methods for forming articles in casting processes.

Innovation Solution

The use of additive manufacturing to create shell-like metal boxes with a lattice structure in the hollow back, providing structural support while minimizing weight and cost, and allowing for the formation of cavities to receive materials like wax or sand for casting processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If metal boxes are used for core, mold, and pattern making, then strength and durability are improved, but weight and cost increase

Engineering Contradiction:

Improvestructural strengthVSAvoidbox weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The box is divided into a shell structure with a hollow back portion rather than a solid construction. The hollow back is further segmented into a lattice structure composed of interconnected struts forming cellular patterns. This segmentation maintains structural strength while significantly reducing weight compared to solid metal boxes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The hollow back portion utilizes a lattice structure that creates a porous-like configuration with interconnected voids. This lattice framework provides structural support through its geometric arrangement rather than through solid material volume, achieving weight reduction while maintaining necessary strength and stiffness for the application.

Inventive Principle:

Principle #31Porous materials

2Strength

If metal boxes are used for core, mold, and pattern making, then strength and durability are improved, but cost increases

Engineering Contradiction:

Improvestructural strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The box is divided into a shell structure with a hollow back portion rather than a solid construction. The hollow back is further segmented into a lattice structure composed of interconnected struts forming cellular patterns. This segmentation maintains structural strength while significantly reducing weight compared to solid metal boxes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The hollow back portion utilizes a lattice structure that creates a porous-like configuration with interconnected voids. This lattice framework provides structural support through its geometric arrangement rather than through solid material volume, achieving weight reduction while maintaining necessary strength and stiffness for the application.

Inventive Principle:

Principle #31Porous materials

3Strength

If solid metal boxes are used, then structural support is improved, but weight and material usage increase

Engineering Contradiction:

Improvestructural supportVSAvoidmaterial usage

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

The box is divided into a shell structure with a hollow back portion rather than a solid construction. The hollow back is further segmented into a lattice structure composed of interconnected struts forming cellular patterns. This segmentation maintains structural strength while significantly reducing weight compared to solid metal boxes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The hollow back portion utilizes a lattice structure that creates a porous-like configuration with interconnected voids. This lattice framework provides structural support through its geometric arrangement rather than through solid material volume, achieving weight reduction while maintaining necessary strength and stiffness for the application.

Inventive Principle:

Principle #31Porous materials

Data Source

PatentUS10646915B2Shell metal core box structure and method

Publication Date: 2020.05.12 HONEYWELL INTERNATIONAL INC

AI summary

A structure and method are provided for forming a box for molding an article for use in casting. A wall defines a cavity formed in a shape of the article and configured to receive a material for forming the article. A rim is disposed around the wall and extends therefrom defining a hollow back on an opposite side of the wall from the cavity. A lattice structure formed in the hollow back and is connected with the wall and with the rim. The box may be formed by additive manufacturing.