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US 2024/0189888 A1Published application
Lost foam and sand casting with polylactic acid-based foam articles
AssigneeLifoam Industries, LLC
InventorSaumitra Bhargava
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Abstract
Methods for forming metal articles are provided. The methods include forming foam casting molds from polylactic acid for use in lost foam and sand casting processes. The PLA-based foam casting molds advantageously reduce cycle time, reduce overall cost, increase reusability of the foam casting molds, reduce costs associated with shipping the foam casting mold, and improve yield and quality of cast metal articles.
Claims23
A method for forming a metal article, the method comprising:
- producing a foam casting mold, wherein producing the foam casting mold comprises:
- producing expandable foam beads formed from polylactic acid,
- molding the beads into a first shape wherein the molded beads correspond to the metal article,
- drying the molded beads, and
- conditioning the molded beads;
- investing the mold in sand;
- casting molten metal into the invested mold;
- removing the cast metal from the sand;
- and
- treating the cast metal to produce the metal article.
7 more elements
Dependencies are inferred from the claim text.