Tiled Casting Moulds with Weakened Seams for Controlled Breaking
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Solution Overview
Problem
Existing casting moulds face challenges in controlled removal, particularly when they include mould inserts, due to limitations in design rules that restrict the shape and complexity of the object being cast, leading to difficulties in ejecting the mould from the casting.
Innovation Solution
The method involves manufacturing moulds and mould inserts as a plurality of pieces connected via weakened seams, using Selective Laser Sintering (SLS) with lower laser power at seam locations, allowing for controlled breaking by applying pressure to specific seams, enabling flexible design and easy removal without compromising rigidity or leaving marks on the casting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If moulds are manufactured as a single piece using precision milling tools, then structural integrity and rigidity are maintained, but removal from complex castings becomes difficult and may damage the casting
Solution Approach 1:
The mould is divided into multiple segments or tiles that are joined by weakened seams. These segments can be separated easily after casting, allowing the mould to be removed from complex castings without damage. The segmentation principle directly resolves the contradiction by enabling easy removal while maintaining sufficient structural integrity during the casting process through the joined segments.
Solution Approach 2:
The seams joining the mould segments are designed with locally reduced strength compared to the segments themselves. This local quality differentiation allows the seams to break easily for mould removal while the segments maintain their structural integrity during casting. The weakened seams are strategically positioned to facilitate removal without compromising the overall mould strength when assembled.
2Adaptability or versatility
If moulds are designed with mould inserts following traditional design rules, then casting complexity can be handled, but design flexibility is limited and ejection becomes difficult
Solution Approach 1:
The mould insert is segmented into multiple tiles joined by weakened seams, allowing it to be ejected as separate pieces after casting. This segmentation enables the handling of complex casting geometries that would be difficult to eject as a single piece, while maintaining design flexibility for various insert configurations.
Solution Approach 2:
The mould insert transitions from a rigid single-piece structure to a dynamically separable segmented structure. The weakened seams allow the insert to change its structural configuration during ejection, breaking apart to navigate complex casting geometries and then potentially being reassembled for reuse, thus enhancing both adaptability and ejection ease.
3Strength
If moulds are made as multiple pieces joined by strong connections, then structural rigidity is maintained, but controlled breaking for removal becomes difficult
Solution Approach 1:
The connections between mould pieces are designed with non-uniform strength distribution: the seams have locally reduced strength compared to the segments. This allows the mould to maintain overall rigidity when assembled for casting, while enabling controlled breaking at the seams during removal. The local quality principle creates a strength gradient that facilitates easy separation without requiring complex breaking mechanisms.
Solution Approach 2:
The weakened seams are pre-designed during manufacturing to facilitate future controlled breaking. The seams are intentionally created with reduced strength characteristics before the casting process, preparing the mould for easy separation after casting without requiring additional force or complex removal mechanisms.
4Ease of operation
If additive manufacturing is used to create moulds with weakened seams, then controlled breaking is enabled, but manufacturing precision at seam locations must be carefully controlled
Solution Approach 1:
Additive manufacturing enables precise local quality control at the seams by varying deposition parameters, layer orientation, or material properties only at the seam locations. This allows the creation of weakened seams with controlled strength reduction while maintaining high precision in the overall mould structure. The additive process naturally facilitates different manufacturing characteristics at different locations, perfectly suited for creating the required strength gradient.
Solution Approach 2:
The additive manufacturing process utilizes parameter changes during deposition to control seam strength. By adjusting laser power, deposition rate, layer thickness, or material composition specifically at seam locations, the manufacturing precision of seam strength is controlled to achieve the desired weakened connection while maintaining overall mould integrity. This parameter control enables reproducible creation of controlled-breaking features.
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 allows for controlled and predefined breaking of moulds into small pieces, facilitating removal from the casting while maintaining structural integrity and avoiding damage, with seam strength tailored to specific applications and materials.
Implementation Method 1
step c) comprises manufacturing the tile pieces by Selective Laser Sintering (SLS). More particularly, step c) is obtained by applying a lower laser power to the positions corresponding to said the spacings or seams than to the positions corresponding to the tile pieces.
Data Source
Figure 1
Figure 2A~2G
Figure 3A~3C
AI summary
Method for the manufacture of object or part thereof such as a casting moulds or mould parts comprising several tile pieces (2,3) and seams (4) between said tile pieces so as to allow controlled breaking of the objects. The application further provides objects such as casting moulds with a tile structure.