Method and apparatus for creating sacrificial patterns and cast parts
First Claim
1. An apparatus for casting parts, comprising:
- a mold incorporating a mold cavity for receiving a casting compound;
a plurality of inter-fitting sections dimensioned to create said mold cavity when assembled;
said inter-fitting sections fabricated from one or more of a class of materials which have the properties of being radiation transparent, yielding to the touch, stretchable, pliable and shape retentive; and
a radiation transparent mold frame comprised of a plurality of sections for containing, stabilizing and holding said inter-fitting sections in said assembled condition for creating said mold cavity.
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Abstract
A process and apparatus for casting three-dimensional parts and sacrificial models from a class of casting compounds which incorporate one or more radiation activated photo initiators which cause polymerization of the casting compound causing it to solidify or transition from a solid in a first state to a solid more suitable for use as a sacrificial model in a lost wax casting process. The class of casting compounds include, 1) compounds which act as conduits for the polymerization initiating radiation during and/or after hardening and 2) compounds which are hardened by a radiation induced chain reaction throughout the body of fluid casting compound. These compounds allow the part being cast to be cured within transparent molds that are supported by transparent mold frames. The apparatus consists of a radiation source positioned to irradiate the casting compound within a mold cavity through the mold frame and mold wall to effect the polymerization, solidifying, process. Separation of the molded part from the mold is enabled by the relative flexibility between the part and mold cavity walls. This is a function of using a soft, flexible material for the mold body and/or a polymerization process which caused the casting compound the solidify into a soft, flexible object. When the polymerized cast part is at least partially removed from the mold, it may be subjected to additional radiation of a frequency different form that initially applied the cause the solid cast part to transition to a hard or ridged part having properties more suitable for a model which is to be used as a sacrificial model in a lost wax process. An automated casting system is anticipated which is enabled by the use of very soft, stretchable and deformable material for the mold body and supporting the mold with radiation transparent mold frames. Oxygen and other gases in the atmosphere react with some casting compounds to create a sticky film on mold cavity walls which causes difficulty when removing a casting from a mold. This problem is eliminated by purging the mold cavity with an inert gas between casts.
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Citations
38 Claims
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1. An apparatus for casting parts, comprising:
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a mold incorporating a mold cavity for receiving a casting compound;
a plurality of inter-fitting sections dimensioned to create said mold cavity when assembled;
said inter-fitting sections fabricated from one or more of a class of materials which have the properties of being radiation transparent, yielding to the touch, stretchable, pliable and shape retentive; and
a radiation transparent mold frame comprised of a plurality of sections for containing, stabilizing and holding said inter-fitting sections in said assembled condition for creating said mold cavity. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29)
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30. An apparatus for casting parts, comprising:
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a mold incorporating a mold cavity;
a plurality of inter-fitting sections dimensioned to create said mold cavity when said inter-fitting sections are assembled as a mold assembly;
said inter-fitting sections fabricated from one or more of a class of materials which have the properties of being radiation transparent, yielding to the touch, stretchable, pliable and shape retentive;
a radiation transparent mold frame comprised of a plurality of sections for containing, stabilizing and holding said inter-fitting sections together as said mold assembly;
a converging conveying means for bringing said plurality of inter-fitting sections together for creating said mold assembly;
said converging conveying means for bringing said plurality of sections of said radiation transparent mold frame together for enclosing said plurality of inter-fitting sections;
means for purging said mold cavity with an inert gas;
means for evacuating said mold cavity for creating a partial vacuum therein;
means for filling said evacuated mold cavity with a casting compound;
means for causing polymerization of said casting compound within said mold cavity by subjecting said casting compound within said mold cavity to a polymerization initiating radiation whereby said casting compound becomes a casting; and
a diverging conveying means for removing said mold frame sections for destabilizing said inter-fitting sections and removing said inter-fitting sections from said casting. - View Dependent Claims (31)
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32. A method for casting parts, including the steps of:
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creating a mold incorporating a mold cavity by assembling a plurality of inter-fitting sections fabricated from one or more of a class of materials which have the properties of being radiation transparent, yielding to the touch, stretchable, pliable and shape retentive which are dimensioned to create said mold cavity;
stabilizing said mold by enclosing it in a radiation transparent mold frame;
purging said mold cavity with an inert gas;
evacuating said mold cavity;
filling said evacuated mold cavity with a casting compound;
subjecting said casting compound within said mold cavity to a polymerizing initiating radiation and thereby causing said casting compound to polymerize into a solid casting;
removing said radiation transparent mold frame from said mold; and
removing said inter-fitting sections from said casting. - View Dependent Claims (33, 34, 35, 36, 37, 38)
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Specification