Method for inorganic binder castings

A method for inorganic binder casting, comprising:

• selecting a Shape-Forming Material based on pre-determined manufacturing and shape characteristics;
• selecting a casting shape based on the pre-determined manufacturing and shape characteristics;
• printing the Shape-Forming Material using an additive manufacturing process to form a first mold;
• creating a first liquid binder solution, the first liquid binder solution including at least 51% inorganic material by weight in a first solvent;
• coating the Shape-Forming Material with the first liquid binder solution;
• substantially dehydrating the coated Shape-Forming Material;
• pouring a liquid metal into the first mold;
• allowing the liquid metal to cool to form a solid molded part;
• removing the Shape-Forming Material from the solid molded part with a second solvent;
• reclaiming the inorganic material for reuse;
• reclaiming the Shape-Forming Material for reuse;
• printing the reclaimed Shape-Forming Material using an additive manufacturing process to form a second mold;
• creating a second liquid binder solution using the reclaimed inorganic material, the second liquid binder solution including at least 51% inorganic material by weight in a third solvent;
• and
• coating the reclaimed Shape-Forming Material with the second liquid binder solution.

A method for inorganic binder casting, comprising:

• selecting a Shape-Forming Material based on pre-determined manufacturing and shape characteristics;
• selecting a casting shape based on the pre-determined manufacturing and shape characteristics;
• utilizing the Shape-Forming Material using a sand mixer process to form a first mold;
• creating a first liquid binder solution, the first liquid binder solution including at least 51% inorganic material by weight in a first solvent;
• coating the Shape-Forming Material with the first liquid binder solution;
• substantially dehydrating the coated Shape-Forming Material;
• pouring a liquid metal into the first mold;
• allowing the liquid metal to cool to form a solid molded part;
• removing the Shape-Forming Material from the solid molded part with a second solvent;
• reclaiming the inorganic material for reuse;
• reclaiming the Shape-Forming Material for reuse;
• utilizing the reclaimed Shape-Forming Material using a sand mixer process to form a second mold;
• creating a second liquid binder solution using the reclaimed inorganic material, the second liquid binder solution including at least 51% inorganic material by weight in a third solvent;
• and
• coating the reclaimed Shape-Forming Material with the second liquid binder solution.