Modular Molding Plates for Flexible Lost Casting Production

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Solution Overview

Problem

Current methods for producing components through lost casting molds are costly and lack flexibility in shaping options, as they require extensive resources and complex mold designs, limiting the efficiency and variety of components that can be mass-produced.

Innovation Solution

A device and method involving a mold building device that layers molding plates to form casting molds, allowing for the creation of complex shapes using multiple plates with simple designs, which can be easily assembled and reused, reducing material waste and production costs by using a variety of materials and binders, and enabling efficient production of components with curved or inclined contours.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional lost casting molds are used for mass production, then components can be produced in series, but the cost of manufacturing is high and flexibility in shape selection is limited

Engineering Contradiction:

Improveseries production capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The casting mold is divided into multiple individual molding plates that can be produced separately and then assembled in layers. Each molding plate can be manufactured independently using cost-effective methods, and the modular structure allows for easy assembly and disassembly, reducing overall manufacturing complexity and cost while maintaining series production capability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The molding plates are designed to be reusable and can be assembled in different combinations to create various casting mold configurations. This universal approach allows the same set of molding plates to serve multiple casting operations, reducing the need for custom molds for each component shape and thereby lowering manufacturing costs

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If traditional lost casting molds are used, then mass production is possible, but flexibility in component shape design is reduced

Engineering Contradiction:

Improvemass production efficiencyVSAvoidshape design flexibility

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

By segmenting the mold into multiple independent molding plates, the system gains flexibility to assemble different plate combinations for various component shapes. This segmentation allows rapid reconfiguration of molds for different casting geometries while maintaining efficient mass production workflows

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The molding plates are designed with dynamic assembly capabilities, allowing them to be easily connected and disconnected to form different mold configurations. This dynamic approach enables quick adaptation to different component shapes without requiring complete mold redesign, thus maintaining both productivity and design flexibility

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If complex casting molds are created for various shapes, then design flexibility is improved, but mold complexity and production cost increase

Engineering Contradiction:

Improvecomponent shape varietyVSAvoidmold design complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Instead of creating single complex molds for each component shape, the system segments the mold into standardized plates that can be combined in various ways. This reduces the complexity of individual mold designs while achieving the same shape variety through combinatorial assembly of simpler components

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple simple molding plates are merged through assembly to create the functional equivalent of complex molds. This combining approach achieves diverse component shapes without requiring each individual mold to be complex, thereby reducing overall device complexity while maintaining adaptability

Inventive Principle:

Principle #5Merging (Combining)

4Productivity

If traditional molding methods are used, then components can be produced, but material waste is high and production costs are elevated

Engineering Contradiction:

Improveproduction efficiencyVSAvoidmaterial waste

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The molding plates are designed to be reusable and can be recovered after each casting operation. Unlike traditional lost molds that are destroyed with the casting, these plates can be disassembled, inspected, and reused for subsequent productions, significantly reducing material waste and lowering production costs over time

Inventive Principle:

Principle #34Discarding and recovering

Data Source

PatentUS12076781B2Device and method for manufacturing components

Publication Date: 2024.09.03 FRAUNHOFER GESELLSCHAFT ZUR FORDERUNG DER ANGEWANDTEN FORSCHUNG EV

AI summary

The invention relates to a device and a method for producing components comprising a mould building device (1) for producing lost casting moulds, and a casting device (2) connected to the mould building device for casting components in the lost casting moulds, characterised in that the mould building device is suitable for the continuous layering of moulding plates (3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23), wherein a respective at least three of said moulding plates form a casting mould.