Additive fabrication technologies for creating molds for die components

Abstract

A method comprising the use of additive manufacturing techniques for creating molds and pattern parts for subsequent use in the casting of die components and die shoes for use in die stamping processes.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application is related to the following applications: U.S. patent application Ser. No. ______, filed on Feb. 29, 2012, entitled “MOLD CORE FOR FORMING A MOLDING TOOL” (Atty. Docket No. 83203377); U.S. patent application Ser. No.______, filed on Feb. 29, 2012, entitled “MOLDING ASSEMBLY WITH HEATING AND COOLING SYSTEM” (Atty. Docket No. 83203379); U.S. patent application Ser. No. ______, filed on Feb. 29, 2012, entitled “INTERCHANGEABLE MOLD INSERTS” (Atty. Docket No. 83203382); U.S. patent application Ser. No. ______, filed on Feb. 29, 2012, entitled “MOLD CORE PACKAGE FOR FORMING A POWDER SLUSH MOLDING TOOL” (Atty. Docket No. 83225801); and U.S. patent application Ser. No. ______, entitled “MOLDING TOOL WITH CONFORMAL PORTIONS AND METHOD OF MAKING THE SAME” (Atty. Docket No. 83225806), the entire disclosures of which are hereby incorporated herein by reference.FIELD OF THE INVENTION[0002]The present invention generally relates to th...

AI Technical Summary

Benefits of technology

The present invention provides methods for making pattern parts for casting die components using polymeric powder and solvents, as well as methods for making mold core packages and sand mold packages using additive manufacturing processes. The methods involve depositing a thin layer of polymeric powder and selectively applying a solvent to create a cross-section of the pattern part, which is then coated with a slurry to form a shell for casting. The methods allow for precise creation of die components with near net configurations. The technical effects of the invention include improved accuracy and efficiency in the casting process.

Problems solved by technology

Thus, it is impractical to cast multiple die components using traditional sand casting methods, which involve tooling up a mold pattern to form a sand core from which the die component is cast.

This machining process lacks the precision needed to cast a near net-shape of the die component.

The multiple rough machine steps are necessary because the extra stock on the cast part often exceeds the penetration depth of the CNC machine, such that the extra stock must first be removed through any number of rough cut operations.

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