Method of forming molds and mold plugs

Abstract

A method of making a mold includes the steps of determining the contours of the part to be produced, forming pattern stations having a surface conforming to a contour of the part at a given location, placing the stations in spaced apart relationship, filling the spaces, vacuum forming a plastic material to a portion and applying a mold making material. An alternative method includes the steps of determining the contours of the part to be produced, forming pattern stations each having a surface conforming to a contour of the part at a given location, joining the stations together such that their surfaces form substantially the complete contour of the part and covering a portion of the pattern with a plastic material. The stations may be releasably joined together such that one or more may be removed and substituted with one or more different stations. Another method includes the steps of determining the contours of the part to be produced, cutting the contours at various locations in sheets of material, joining the sheets together to form a cavity corresponding to the contours of the part, vacuum forming a plastic material in the cavity, and applying a mold making material.

Dependencies are inferred from the claim text.