Vacuum Formed Disposable Mold for Small Batch Casting
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Solution Overview
Problem
The production of components in small quantities using permanent molds is cost-effective for large quantities but becomes economically inefficient due to the high manufacturing and storage costs of these molds.
Innovation Solution
A method and casting system that uses an elastic film to create a mold by vacuum-forming molding material in a molding box, allowing for the production of components without the need for permanent molds, thus reducing production and storage costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If permanent molds are used for casting components, then manufacturing precision and component quality are improved, but manufacturing cost and storage cost increase significantly for small quantity production
Solution Approach 1:
The patent uses disposable molds made from inexpensive materials such as plaster, sand, or foam instead of permanent molds. These molds are destroyed after a single use to remove the cast component, eliminating the need for costly permanent mold manufacturing and storage while maintaining adequate component quality for small production runs
Solution Approach 2:
The patent changes the material parameters of the mold from permanent, durable materials to temporary, consumable materials. The mold material is selected based on the specific casting requirements and is designed to be destroyed after use, transforming the mold from a reusable asset to a disposable tool that reduces overall manufacturing cost
2Productivity
If permanent molds are manufactured for various components, then production capability is improved, but storage requirements and associated costs increase
Solution Approach 1:
By using disposable molds that are destroyed after each casting operation, the patent eliminates the need for long-term storage of multiple permanent molds. Each mold serves its purpose immediately and is then discarded, reducing storage volume requirements to minimal or zero for the mold inventory
3Ease of manufacture
If disposable molds made from inexpensive materials are used, then manufacturing cost is reduced, but manufacturing precision and surface quality may deteriorate
Solution Approach 1:
The patent employs flexible membrane liners made from materials such as plastic film, rubber, or silicone that are placed inside the disposable mold cavity. These thin films provide a smooth, precise surface that transfers high-quality impressions to the cast component, while the disposable mold itself can be made from inexpensive materials like plaster or foam
Solution Approach 2:
The patent creates a composite mold structure combining an inexpensive disposable mold body (plaster, sand, or foam) with a flexible membrane liner (plastic film, rubber, or silicone). This composite approach allows the mold to be both cost-effective and capable of producing high-surface-quality components through the smooth membrane interface
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
Enables cost-effective production of components in small quantities by eliminating the need for permanent molds, allowing for complex geometries and high surface quality, and facilitating the reuse of mold material.
Implementation Method 1
an elastic film is arranged on a model by means of a vacuum
Implementation Method 2
A vacuum is then created in the molding box, with the molding material being stabilized by the vacuum so that the mold is formed
Data Source
Figure 1a~1c
Figure 1d~1f
Figure 1g~1h
AI summary
The invention relates to a method and a casting system for casting components with a casting compound, wherein an elastic film is arranged on a model by means of a vacuum, wherein the model is arranged in a molding box (25), wherein the molding box is filled with a molding material (27), wherein a mold (32) is formed by applying a vacuum to the molding material in the molding box, wherein the model is removed and a cavity (33) is formed in the mold, wherein a casting compound (11) is filled into the cavity and cured to form a component, wherein the component is demolded.