Computational Design of Segmented Flexible Molds for Complex Objects
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Solution Overview
Problem
Existing methods for designing re-usable flexible molds for object reproduction are limited in efficiently calculating the strain upon removal and optimizing the parting line, leading to potential damage to the mold or object during the casting process.
Innovation Solution
A computational method that takes a digital surface description of the object, separates it into connected surface patches based on heuristic estimation or volume-based calculation models, and calculates a two-pieced flexible mold for non-destructive casting, allowing for variable number of mold pieces and optimal orientation to minimize air bubble formation and ensure easy removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-pieced flexible mold is used, then the mold structure is simple, but the mold cannot be removed from complex objects without causing damage
Solution Approach 1:
The flexible mold is divided into multiple pieces (first flexible mold piece and second flexible mold piece) that can be separated from each other. This segmentation allows the mold to be removed from complex objects by disassembling into multiple components, solving the problem of inability to remove single-pieced molds from intricate geometries while avoiding the need for a completely complex single-piece structure
2Adaptability or versatility
If the flexible mold is made more flexible to accommodate complex shapes, then the mold can reproduce detailed objects, but the mold becomes more prone to damage during removal
Solution Approach 1:
By dividing the flexible mold into multiple pieces, each piece can be designed with appropriate flexibility for its specific function while the overall system maintains durability through the distributed structure. The segmentation reduces stress concentration on any single piece during removal operations
Solution Approach 2:
The flexible mold pieces are designed to dynamically adapt to the object shape during casting, then dynamically separate during removal. The mold transitions from a unified flexible structure during filling to separated pieces during extraction, optimizing both shape accommodation and damage prevention
3Ease of operation
If the number of mold pieces is increased to achieve non-destructive casting, then the mold can be removed from complex objects, but the manufacturing complexity increases
Solution Approach 1:
The mold is segmented into a specific number of pieces (first and second pieces) based on the object geometry and removal requirements. This controlled segmentation achieves non-destructive casting by providing enough pieces to navigate complex geometries while limiting the total number to avoid excessive manufacturing complexity
Solution Approach 2:
The mold pieces are separated along a parting line that introduces a new dimensional aspect to the mold structure. This parting line creates a separation plane that enables piece separation without requiring an excessive number of pieces, effectively using dimensional separation to manage complexity
4Ease of manufacture
If the parting line is not optimized, then the mold design is simpler, but strain during removal exceeds material limits causing damage
Solution Approach 1:
The parting line is determined in advance during the mold design phase, before actual casting and removal operations. This preliminary determination of the parting line allows optimization of strain distribution to ensure it remains within material limits during removal, preventing damage while avoiding complex real-time adjustments
Data Source
AI summary
The invention relates to a method for computationally designing re-usable silicone molds for the reproduction of an object, wherein the silicone mold is fillable with casting material, for example, but not limited to, resin, to form the object.