Method for laminate forming a sand mould and a method for producing a casting using the same

A method for forming a sand mould as a 3-dimensional form comprising the steps of:

• (a) forming a sand layer by accumulating sand coated with a thermosetting resin in the form of a thin layer;
• (b) arranging a mask having an opening in a predetermined portion above the formed sand layer;
• (c) heating a portion of the sand layer located below the opening through the arranged mask to solidify the portion;
• (d) forming one layer of a sectional form of the sand mould;
• and
• (e) piling up sectional forms to form a sand mould as a 3-dimensional form by repeating steps (a)-(d);
• wherein the mask is manufactured based on a mask form obtained after the arrangement of supports by the following steps:
• creating a mask for based on a 2-dimensional sectional form of a casting form;
• and
• automatically arranging supports at predetermined intervals in the space;
• portion surrounding the detected island portion based on parallel lines arranged at predetermined intervals.

A method for forming a sand mould as a 3-dimensional form comprising the steps of:

• (a) forming a sand layer by accumulating sand coated with a thermosetting resin in the form of a thin layer;
• (b) arranging a mask having an opening in a predetermined portion above the formed sand layer;
• (c) heating a portion of the sand layer located below the opening through the arranged mask to solidify the portion;
• (d) forming one layer of a sectional form of the sand mould;
• and
• (e) piling up sectional forms to form a sand mould as a 3-dimensional form by repeating steps (a)-(d);
• wherein the mask is manufactured based on a mask form obtained after the arrangement of supports by the following steps:
• creating a mask form based on a 2-dimensional sectional form of a casting form;
• detecting an island portion surrounded by a space portion from the thus created mask form;
• and
• automatically arranging supports in the space portion surrounding the detected island portion based on a lattice of supports arranged at predetermined intervals.

A method for forming a sand mould as a 3-dimensional form comprising the steps of:

• (a) forming a sand layer by accumulating sand coated with a thermosetting resin in the form of a thin layer;
• (b) arranging a mask having an opening in a predetermined portion above the formed sand layer;
• (c) heating a portion of the sand layer located below the opening through the arranged mask to solidify the portion;
• (d) forming one layer of a sectional form of the sand mould;
• and
• (e) piling up sectional forms to form a sand mould as a 3-dimensional form by repeating (a)-(d);
• wherein the mask is manufactured based on a mask form obtained after the arrangement of supports has been changed by the following steps:
• creating a mask for based on a 2-dimensional sectional form of a casting form;
• detecting an island portion surrounded by a space portion from the thus created mask form;
• automatically determining the arrangement positions of supports for supporting the island portion based on predetermined rules;
• and
• changing the position of an automatically arranged support according to a connection state between the island portion and the support.

A method for forming sand mould for producing a casting using the sand mould comprising the steps of:

• (a) forming a sand layer by accumulating sand coated with a thermosetting resin in the form of a thin layer;
• (b) arranging a mask having an opening in a predetermined portion above the formed sand layer;
• (c) heating a portion of the sand layer located below the opening through the arranged mask to solidify the portion by irradiating a diffused laser beam onto the sand layer through the mask to heat an exposed portion of the sand layer;
• (d) thereby forming one layer of a sectional form of the sand mould;
• (e) piling up sectional forms to form a sand mould as a 3-dimensional form by repeating steps (a)-(d);
• and
• producing a casting using the thus obtained sand mould.

An apparatus for forming a sand mould as a 3-dimensional form comprising:

• a sand layer forming device for forming a sand layer by accumulating sand coated with a thermosetting resin in the form of a thin layer;
• a mask having an opening in a predetermined portion and changeably arranged above the formed sand layer;
• a mask changer for changing the mask arranged above the formed sand layer;
• and
• A diffused laser irradiating unit above the mask for irradiating a laser beam onto a portion of the sand layer located below the opening through the arranged mask to solidify the portion.