Segmented Negative Mould Formwork for Complex Master Forming
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Solution Overview
Problem
Existing master moulding processes struggle to produce non-standard and non-repetitive geometries efficiently, leading to high costs and waste generation due to the use of conventional devices that are expensive and time-consuming to manufacture.
Innovation Solution
A method involving a flat initial semi-finished product is deformed to create a three-dimensional structure with partial surfaces in different planes, forming a negative mould that can be used with or without a supporting structure, allowing for the production of complex geometries using materials like cardboard, PET, or metal sheets, and enabling reuse or recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional formwork systems (wood or metal shutters) are used for master forming processes, then structural strength and reusability are improved, but manufacturing cost and material waste increase significantly
Solution Approach 1:
The formwork is divided into a supporting structure (providing strength) and a negative mould (defining geometry). The negative mould can be made from thin, recyclable materials like cardboard or PET sheets, while the supporting structure bears the load. This segmentation allows the moulding part to be inexpensive and disposable/recyclable, while the structural part remains reusable.
Solution Approach 2:
The negative mould is made from inexpensive materials such as cardboard, PET sheets, or thin metal sheets that can be easily replaced or recycled after use. This eliminates the need for expensive, durable materials for the entire formwork system, significantly reducing material waste and manufacturing cost.
2Stability of the object's composition
If thick materials are used to build master mould structures for non-standard geometries, then structural stability is improved, but manufacturing time and cost increase
Solution Approach 1:
The invention transitions from building three-dimensional mould structures to using two-dimensional flat sheets that are bent or folded into shape. This dimensional reduction allows for faster manufacturing using standard sheet materials, while the resulting three-dimensional form provides the necessary stability for the master forming process.
3Adaptability or versatility
If flexible formwork systems are used to realize single and double curved geometries, then geometric versatility is improved, but structural strength and material durability decrease
Solution Approach 1:
The formwork is segmented into a rigid supporting structure that provides strength and a flexible negative mould that provides geometric versatility. The negative mould can be made from flexible materials like cardboard or thin PET sheets that can be easily shaped into complex geometries, while the supporting structure maintains overall structural integrity.
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 enables cost-saving and resource-efficient production of master forming parts with complex geometries, facilitating easy assembly, casting, and demoulding, while reducing waste and material costs.
Implementation Method 1
a flat initial semi-finished product is deformed in a bending process in such a way that the initial semi-finished product is given a three-dimensional structure as a negative mould on one side
Data Source
AI summary
A method for manufacturing a device for a master forming process and a master forming process. In the method for manufacturing a device for a master forming process a flat initial semi-finished product is provided and this initial semi-finished product is deformed in a bending process such that the initial semi-finished product is given a three-dimensional structure as a negative mould on one side via a plurality of partial surfaces running in different planes. The plurality of partial surfaces are configured to delimit a component produced via a master forming process using the device on one side in the master forming process. A supporting structure is provided and the negative mould is arranged at or on or around the supporting structure such that the negative mould and an amorphous material to be arranged thereon is supported or supportable by the supporting structure in the master forming process.