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Method of reducing distortion in a spray formed rapid tool

  • US 6,179,039 B1
  • Filed: 03/25/1999
  • Issued: 01/30/2001
  • Est. Priority Date: 03/25/1999
  • Status: Expired due to Term
First Claim
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1. A method of reducing distortion in a spray formed rapid tool comprising the steps of:

  • making a model of a desired tool;

    constructing a ceramic pattern as the inverse of the model;

    building a thermal model of the desired tool from a solid model of the ceramic pattern;

    applying thermal boundary conditions to the thermal model based on known conditions;

    running the thermal model to produce a temperature distribution of the desired tool and determining any temperature deviations in the temperature distribution above a predetermined value; and

    thermally spraying a metal material against the ceramic pattern to form the desired tool if there are no temperature deviations in the temperature distribution above the predetermined value.

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