Techniques for casting from additively fabricated molds and related systems and methods

Patent metadata

Field	Value
Publication number	US-11097449-B2
Application number	US-201815981279-A
Country	US
Kind code	B2
Filing date	May 16, 2018
Priority date	May 17, 2017
Publication date	Aug 24, 2021
Grant date	Aug 24, 2021

Abstract

According to some aspects, a method is provided of casting an object from a mold, the method comprising obtaining a mold comprising a hollow shell of rigid material, the material comprising a thermoset polymer having a plurality of pores formed therein, providing a metal and/or ceramic slurry into an interior of the mold, exposing at least part of the mold to a low pressure environment so that a net flow of gas is produced from the interior of the mold into the low pressure environment. According to some aspects, a method of forming a porous mold is provided. According to some aspects, a photocurable liquid composition is provided, comprising a liquid photopolymer resin, particles of a solid material, in an amount between 30% and 60% by volume of the composition, and a water-soluble liquid.

First claim

What is claimed is:

1. A method of removing an object from a mold, the method comprising:
obtaining an object formed within a mold, the mold comprising a shell of rigid material that comprises a thermoset polymer, the shell having a plurality of pores formed therein, and the object comprising a solidified metal and/or ceramic slurry;
applying a solvent to the mold, thereby softening but not dissolving the mold; and
mechanically removing the softened mold from the object.

2. The method of claim 1 , wherein the solvent comprises acetone.

3. The method of claim 1 , wherein applying the solvent to the mold comprises immersing the mold in a bath of the solvent.

4. The method of claim 1 , further comprising cooling the object prior to mechanically removing the mold from the object.

5. The method of claim 4 , wherein the solvent has at a temperature below a temperature of the object such that said cooling of the object is performed, at least in part, by applying the solvent to the mold.

6. The method of claim 1 , wherein a mean size of the plurality of pores is between 40 μm and 60 μm.

7. The method of claim 1 , wherein the rigid material further comprises a plurality of fibers.

Assignees

• Formlabs Inc

Inventors

• Mccarthy Alex
• Lobovsky Maxim
• Galese Martin

Classifications

• B29C39/36 Primary

  Removing moulded articles · CPC title

• B22F3/22

  for producing castings from a slip · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B29C33/52

  soluble or fusible {(in particular used in injection moulding B29C45/4457)} · CPC title

• B29C33/3842 Primary

  Manufacturing moulds, e.g. shaping the mould surface by machining · CPC title