Method of making a hollow tool

Abstract

A method and apparatus for making a hollow tool which is used to impart shape to an article. The method comprises: (a) building an outer box around a model of the article; (b) constructing an inner box disposed within and spaced apart from the outer box; (c) applying a fluid laminating agent to an inside surface of the inner box and to the model; (d) removing the inner box after the fluid laminating agent cures to form a solidified shell; (e) supporting the shell so that a space is formed between it and the model; (f) pouring a filling agent into the space, the filling agent bonding to the shell and forming a face that replicates the model; and (g) installing a support structure inside the shell to form the hollow tool, thereby imbuing the tool with the physical characteristics of lightness in weight and durability in shape retention after prolonged exposure to thermal cycling and the thermal characteristics of a uniform heat conductivity over all sections of the tool, regardless of its outside dimensions. The apparatus of the present invention includes a hollow tooling apparatus used to impart shape to an article of manufacture. The tooling apparatus comprises a support structure disposed inside the shell to form the hollow tool.

Dependencies are inferred from the claim text.