Patternless Sand Mold Formation via Layered Curing and Machining

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Solution Overview

Problem

The existing metal casting processes, particularly those using sand molds, face challenges in achieving rapid and cost-effective production of complex shapes without the need for intermediate patterns, which are time-consuming and costly to create.

Innovation Solution

A method and device for manufacturing sand molds using an additive and subtractive layered manufacturing process, integrating layer deposition techniques and CNC machining, where sand layers are cured and machined to form precise mold surfaces, allowing for the direct creation of mold shapes from digital designs without intermediate patterns.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional patterned mold making is used, then mold shape accuracy is achieved, but production time and cost increase significantly

Engineering Contradiction:

Improvemold shape accuracyVSAvoidproduction time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The mold making process is segmented into discrete layers that are deposited and cured sequentially. Each layer is independently formed and cured, allowing for automated layer-by-layer construction without requiring traditional pattern fabrication, thereby reducing production time while maintaining accuracy through controlled layer deposition

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The sand layers are pre-cured using UV light or other curing methods before final assembly. This preliminary curing action stabilizes the mold structure early in the process, enabling faster production cycles while ensuring dimensional accuracy is maintained throughout subsequent handling and assembly operations

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If traditional patterned mold making is used, then mold shape accuracy is achieved, but manufacturing cost increases

Engineering Contradiction:

Improvemold shape accuracyVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The mold is created by depositing and curing successive layers of sand material according to digital design data, effectively copying the desired mold geometry directly without requiring physical patterns. This digital-to-physical copying process eliminates the need for expensive pattern fabrication and tooling, reducing manufacturing costs while maintaining high shape accuracy through precise digital control

Inventive Principle:

Principle #26Copying

Solution Approach 2:

Traditional mechanical pattern-making processes are replaced with automated layer deposition and curing systems controlled by digital models. This substitution of mechanical craftsmanship with automated deposition and UV curing technology reduces labor costs and material waste while maintaining or improving mold shape accuracy

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If additive manufacturing is used for mold creation, then production speed increases, but process complexity increases

Engineering Contradiction:

Improvemold production speedVSAvoidprocess complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The layer deposition system and UV curing system are merged into an integrated automated process. The same robotic or automated mechanism that deposits sand layers also positions and activates the UV curing source, combining multiple functions into a unified system that increases production speed while managing complexity through integration rather than separate independent systems

Inventive Principle:

Principle #5Merging (Combining)

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 increases mold production speed and precision, reducing the time and cost associated with traditional patterned mold making, enabling rapid prototyping and production of complex metal castings with high accuracy and tolerance.

Implementation Method 1

At least a portion of the first layer of sand is cured. Any portion of the first layer that is cured is a first cured portion

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Data Source

PatentUS9901977B2Patternless sand mold and core formation for rapid casting

Publication Date: 2018.02.27 WESTERN MICHIGAN UNIVERSITY

AI summary

A method of creating a sand mold for rapid casting, including the steps of determining a mold shape, providing a generally uniform thickness layer of sand, curing at least a portion of the layer of sand, machining the cured portions of the layer of sand based on the desired mold shape, and repeating the layer-forming, curing and machining steps until the sand mold is complete. Another aspect includes a machine for creating the sand mold having a build envelope defined by side walls, a movable build platform and at least one movable tool assembly, the movable tool assembly having a single or plurality of tools chosen from the group consisting of a sand dispenser, a sand leveling device, a curing device, and a machining device.