Tool-less method for making molds, cores, and temporary tools
AssigneeLightSpeed Concepts Inc.
InventorsJohn P. Biel, Jr., Brandon Michael Welker, John R. Keough, Thomas Allen Cobett, Julie Ruth Nimer
Life of this patent
Estimating the term…
Abstract
A tool-less method for making molds, cores, and temporary tools includes the steps of providing a volumetric build system, making a CAD model of a three-dimensional object, selecting a build material including an untreated sand, selecting a binder comprising a polymeric carbohydrate, and applying, by the volumetric build system, the binder onto the build material to three dimensionally print the object, wherein the object is adapted for being a mold, a core, or a temporary tool.
Claims26
A method for producing bonded sand shapes adapted to be used as molds and cores for a metal casting process, said method comprising the steps of:
- providing an additive volumetric build system having a print bed;
- making a CAD model of a three-dimensional object;
- selecting a build material comprising untreated sand;
- selecting a single component binder consisting of starch and an aqueous liquid carrier comprising water in a range of about 40 weight percent to 80 weight percent and forming a binder composition;
- applying the untreated sand in layers repeatedly by the additive volumetric build system by printing in both directions a length of the print bed;
- applying the binder composition to selective areas of the layers of the untreated sand without precoating the untreated sand to form a solid shape of the object;
- heating the applied binder composition with an infrared device or microwave device;
- dehydrating the applied binder composition to form a solid bond between grains of the applied binder composition sand;
- and
- removing unbonded and untreated sand from around the bonded sand shape.
A method for producing bonded sand shapes adapted to be used as molds and cores for a metal casting process comprising the steps of:
- obtaining a representation of a three-dimensional object;
- selecting a build material comprising untreated sand;
- selecting a single component binder consisting of starch and an aqueous liquid carrier comprising water in a range of about 40 weight percent to 80 weight percent and forming a binder composition;
- using the representation of the object, applying the untreated sand in layers, and applying the binder composition to selective areas of the layers of the untreated sand without precoating the untreated sand to form a solid shape of the object;
- heating the applied binder composition with an infrared device or microwave device;
- dehydrating the applied binder composition to form a solid bond between grains of the applied binder composition sand;
- and
- removing loose, unbonded and untreated sand from around the bonded sand shape.
A method for producing bonded sand shapes adapted for use as molds and cores for a metal casting process, said method comprising the steps of:
- applying untreated sand to form layers repeatedly made by a CAD driven additive system having a print bed and printing in both directions a length of the print bed;
- applying a single component binder consisting of starch and an aqueous liquid carrier comprising water in a range of about 40 weight percent to 80 weight percent and forming a binder composition to selective areas of each of the layers where the untreated sand is to form a solid shape without precoating the untreated sand;
- passing the binder composition through a plurality of inkjet printheads that cover a width of the print bed width;
- heating the applied binder composition with an infrared device or microwave device;
- dehydrating the applied binder composition to form a solid bond between grains of the applied binder composition sand;
- removing the loose, unbonded and untreated sand from around the bonded sand shape;
- removing the bonded sand shape from the additive system and using the hardened sand shapes as molds, and/or cores, without post curing, to make metal castings.
Dependencies are inferred from the claim text.