Metal Casting Methods in Microgravity and Other Environments
AssigneeMade In Space, Inc.
InventorsMichael Snyder, Matthew Napoli, Jason Dunn, Aaron Kemmer
Life of this patent
Estimating the term…
Abstract
Apparatus and methods for creating cast metal objects in space and other environments. Molds are created using additive manufacturing and are injected with a castable metal having a melting point lower than a mold melting point. In some aspects, the additive manufacturing device and the metal casting unit are contained in the same unit.
Claims30
A casting apparatus operable in a microgravity environment, configured to cast objects using a mold created by an additive manufacturing device, the casting apparatus comprising:
- an additive manufacturing device comprising an additive manufacturing device feedstock source providing feedstock to the additive manufacturing device for making the mold;
- and
- a casting formation unit comprising:
- an enclosure;
- an injector configured to inject a castable material into the mold;
- a castable material source supplying the castable material to the injector;
- and
- a mold retaining device configured to retain the mold and position the mold in fluidic contact with the injector;
- wherein the enclosure is configured to prevent contamination of an outside environment by the castable material and the feedstock.
A casting apparatus, configured to create multi-material objects using a part created by an additive manufacturing device, the metal casting apparatus comprising:
- an additive manufacturing device comprising an additive manufacturing device feedstock source providing feedstock to the additive manufacturing device for making the part;
- and
- a casting formation unit comprising:
- an enclosure;
- an injector configured to inject a castable material into the part;
- a metal source supplying the castable material to the injector;
- and
- a part retaining device configured to retain the part and position the part in fluidic contact with the injector;
- wherein the enclosure is configured to prevent contamination of an outside environment by the castable material and the feedstock;
- and
- wherein the part comprises a plurality of capillaries, each of the plurality of capillaries having a width chosen to facilitate microgravity capillary action of a molten castable material injected therein.
A method of casting a metal object in an additively manufactured mold via a space-based metal casting apparatus comprising a metal injector including a heater, and a metal source, the method comprising the steps of:
- (a) receiving a mold at the metal casting apparatus, the mold created by an additive manufacturing device and comprising an injection point configured to receive metal from the injector, a casting cavity and at least one vent cavity connected to the casting cavity via at least one channel, the mold forming a fluidic connection with the metal injector;
- (b) heating a portion of the metal source via the heater, forming molten metal;
- and
- (c) injecting, via the metal injector, the molten metal into the mold.
A method of creating a multi-material part via additive manufacturing and space-based metal casting utilizing a metal casting apparatus comprising a metal injector including a heater, and a metal source, the method comprising the steps of:
- (a) creating, via an additive manufacturing device, a part having a molten metal injection point and a structure comprising a plurality of capillaries, each of the plurality of capillaries having a width chosen to facilitate microgravity capillary action of a molten metal injected therein;
- (b) receiving the part at the metal casting apparatus;
- (c) forming a fluidic connection between the molten metal injection point and the injector;
- (d) heating a portion of the metal source via the heater, forming molten metal;
- and
- (e) injecting, via the metal injector, the molten metal into the part.
Dependencies are inferred from the claim text.