# US 2025/0144705 A1 · Additive casting deposition system and method

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- Number: US 2025/0144705 A1
- Document ID: US20250144705A1
- Status: Published application
- Kind: A1
- Application number: 18/837,615
- Filed: 2023-03-01
- Published: 2025-05-08
- Earliest claimed: 2022-03-01
- Assignees: Magnus Metal Ltd.
- Applicants: Magnus Metal Ltd.
- Inventors: Gil LAVI; Ido HOLCMAN
- Web page: https://patentgrep.com/patent/US20250144705A1

## CPC

- B22D 23/00: Casting processes not provided for in groups B22D1/00 - B22D21/00 (making metallic powder by casting B22F9/08; alumino-thermic welding B23K23/00; remelting metals C22B9/16)
- B22C 9/22: Moulds for peculiarly-shaped castings
- B22F 10/14: by jetting of binder onto a bed of metal powder
- B22F 10/22: Direct deposition of molten metal
- B22F 10/30: Process control
- B22F 10/43: characterised by material
- B22F 10/85: for controlling or regulating additive manufacturing processes
- B22F 12/10: Auxiliary heating means
- B22F 12/13: to preheat the material
- B22F 12/20: Cooling means
- B22F 12/53: Nozzles
- B22F 12/55: Two or more means for feeding material
- B33Y 10/00: Processes of additive manufacturing
- B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor
- B33Y 40/20: Post-treatment, e.g. curing, coating or polishing
- B33Y 50/02: for controlling or regulating additive manufacturing processes
- B33Y 80/00: Products made by additive manufacturing
- B22F 10/50: Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
- B22F 12/90: Means for process control, e.g. cameras or sensors
- B28B 1/001: {Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material (selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00)}
- Y02P 10/25: Process efficiency
- B22D: CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES (shaping of plastics or substances in a plastic state B29C; metallurgical processing, selection of substances to be added to metal C21, C22)
- B22C: FOUNDRY MOULDING (moulding refractory materials in general B28B)
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B)
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

A casting system for casting an object, the system comprises a mold powder provision system, a mold binder dispensing system, a mold powder removal system, and a molten metal processing system. The casting system is configured to additively produce multiple production layers in a build unit, one currently-produced production layer after the other. For each currently-produced production layer, the mold powder provision system is configured to provide one or more current mold powder layers; the mold binder dispensing system is configured to form one or more current metal-facing zones of the mold regions within each of the one or more current mold powder layers by selectively dispending one or more binders that bond some mold powder particles of the current mold powder layer; the mold powder removal system is configured to remove mold powder particles located within a certain area of the current mold powder layers, the certain area is defined by the current metal facing zones of the mold regions; and the molten metal processing system is configured to form one or more current object regions of the currently-produced production layer by providing molten metal to the certain area.

## Claims

### Claim 1

A casting system for casting an object, wherein the system comprises:
a mold powder provision system;
a mold binder dispensing system;
a mold powder removal system; and
a molten metal processing system;
wherein the casting system is configured to additively produce multiple production layers in a build unit, one currently-produced production layer after the other;
wherein for each currently-produced production layer:
the mold powder provision system is configured to provide one or more current mold powder layers;
the mold binder dispensing system is configured to form one or more current metal-facing zones of the mold regions within each of the one or more current mold powder layers by selectively dispending one or more binders that bond some mold powder particles of the current mold powder layer;
the mold powder removal system is configured to remove mold powder particles located within a certain area of each of the one or more current mold powder layers, the certain area is defined by at least some of the one or more current metal facing zones of the mold regions; and
the molten metal processing system is configured to form one or more current object regions of the currently-produced production layer by providing molten metal to the certain area.

### Claim at position 2

2-5. (canceled)

### Claim 6 (depends on 1)

The casting system according to claim 1 wherein a height of the one or more current object regions is in a range of 1 millimeter to 20 millimeter, and wherein a height of the one or more current mold powder layers is in a range of 100 microns to 150 microns.

### Claim 7 (depends on 1)

The casting system according to claim 1 wherein the mold powder removal system is configured to remove the mold powder particles from the certain area and maintain loose mold powder at one or more external zones which are external to the one or more current metal facing zones of the mold regions.

### Claim 8

(canceled)

### Claim 9 (depends on 1)

The casting system according to claim 1 wherein the mold powder removal system comprises flow control elements that are configured to provide suction directly above the certain area and prevent suction directly above loose mold powder located outside the certain area.

### Claim 10 (depends on 1)

The casting system according to claim 1 wherein the mold powder removal system comprises a suction conduit that is configured to be lowered into the certain area during powder suction.

### Claim at position 8

11-21. (canceled)

### Claim 22 (depends on 1)

The casting system according to claim 1 wherein at least one of the mold powder provision system, mold binder dispensing system and the mold powder removal system is thermally shielded at least in part.

### Claim 23 (depends on 1)

The casting system according to claim 1 further comprising a controller in data communication with at least the mold powder provision system, mold binder dispensing system, the mold powder removal system, the molten metal processing system and the build unit, wherein at least one of the mold powder provision system, mold binder dispensing system and the mold powder removal system is equipped with a controllable cooling unit, and wherein the controller is configured to dynamically control the controllable cooling unit responsive to temperature sensor readings of one or more areas of the build unit.

### Claim 24 (depends on 1)

The casting system according to claim 1 further comprising a controller in data communication with at least the mold powder provision system, mold binder dispensing system, the mold powder removal system, the molten metal processing system and the build unit, wherein the controller responsive to readings of one or more temperature sensors sensing one or more temperatures of one of the certain area and the metal facing zone of the mold region.

### Claim at position 12

25-28. (canceled)

### Claim 29 (depends on 1)

The casting system according to claim 1 wherein the mold binder dispensing system comprises one or more binder print heads and one or more binder storages, each binder storage is in fluid communication with at least one of the one or more binder print heads.

### Claim at position 14

30-33. (canceled)

### Claim 34 (depends on 29)

The casting system according to claim 29, further comprising a controller in data communication with at least the mold powder provision system, mold binder dispensing system, the mold powder removal system, the molten metal processing system and the build unit, wherein the controller is responsive to readings of a temperature sensor sensing a temperature beneath the one or more print heads.

### Claim 35

(canceled)

### Claim 36

A method for casting an object, wherein the method comprises:
additively producing multiple production layers, one currently-produced production layer after the other; wherein for each currently-produced production layer:
providing, by a mold powder provision system, one or more current mold powder layers;
forming, by a mold binder dispensing system, one or more current metal-facing zones of the mold regions within each of the one or more current mold powder layers by selectively dispending one or more binders that bond some mold powder particles of the current mold powder layer;
removing, by a mold powder removal system, mold powder particles located within a certain area of the one or more current mold powder layers, the certain area is defined by at least some of the one or more current mold regions; and
forming, by a molten metal processing system, one or more current object regions of the currently-produced production layer by providing molten metal to the certain area.

### Claim at position 18

37-39. (canceled)

### Claim 40 (depends on 36)

The method according to claim 36 wherein a height of the one or more current object regions is in a range of 1 millimeter to 20 millimeter and wherein a height of the one or more current mold powder layers is in a range of 100 microns to 150 microns.

### Claim 41

(canceled)

### Claim 42 (depends on 36)

The method according to claim 36 wherein the removing of the mold powder particles from the certain area comprises maintaining loose mold powder at one or more external zones which are external to the one or more current metal facing zones of the mold regions.

### Claim 43

(canceled)

### Claim 44 (depends on 36)

The method according to claim 36 wherein the removing of the mold powder particles from the certain area comprises utilizing flow control elements to provide suction directly above the certain area and prevent suction directly above loose powder located outside the certain area.

### Claim at position 24

45-55. (canceled)

### Claim 56 (depends on 36)

The method according to claim 36 further comprising thermally shielding at least one of the mold powder provision system, mold binder dispensing system and the mold powder removal system at least in part.

### Claim 57 (depends on 36)

The method according to claim 36 further comprising cooling at least one of the mold powder provision system, mold binder dispensing system and the mold powder removal system by a controllable cooling unit.

### Claim at position 27

58-63. (canceled)

### Claim 64

The method according to 57, wherein the cooling comprises responding to readings of a temperature sensor sensing a temperature beneath one or more print heads of the binder dispensing system.

### Claim 65 (depends on 57)

The method according claim 57, wherein the cooling comprises responding to readings of one or more temperature sensors sensing one or more temperatures of one of the certain area and the metal facing zone of the mold region.

### Claim 66

A non-transitory computer readable medium for casting an object, wherein the non-transitory computer readable medium stores instructions for:
additively producing multiple production layers, one currently-produced production layer after the other; wherein for each currently-produced production layer:
providing, by a mold powder provision system, one or more current mold powder layers;
forming, by a mold binder dispensing system, one or more current metal-facing zones of the mold regions within each of the one or more current mold powder layers by selectively dispending particles of one or more binders that bond some mold powder particles of the current mold powder layer;
removing, by a mold powder removal system, mold powder particles located within a certain area of the one or more current mold powder layers, the certain area is defined by at least some of the one or more current mold regions; and
forming, by a molten metal processing system, one or more current object regions of the currently-produced production layer by providing molten metal to the certain area.

### Claim at position 31

67-69. (canceled)

### Claim 70 (depends on 1)

The casting system according to claim 1 further comprising a movement system configured to introduce relative movements between at least (1) the mold powder provision system, mold binder dispensing system and the mold powder removal system and (2) the build unit.