Method for constructing a metal mold

Patent metadata

Field	Value
Publication number	US-2025387954-A1
Application number	US-202519307921-A
Country	US
Kind code	A1
Filing date	Aug 22, 2025
Priority date	Jan 12, 2024
Publication date	Dec 25, 2025
Grant date	—

Abstract

A part formed by additive manufacturing includes a plurality of layers including a first layer and a second layer, the first layer and the second layer being stacked along a stacking direction, and a work surface formed on an upper surface of the first layer and an upper surface of the second layer. The part also includes a first through-hole formed in the first layer, a second through-hole formed in the second layer, the second through-hole being at least partially aligned with the first through-hole, and a wall extending from the first through-hole to the work surface.

First claim

What is claimed is:

1 . A part formed by additive manufacturing, the part comprising:
a first layer of a plurality of layers; a second layer of the plurality of layers, the first layer in contact with the second layer to form a portion of a mold surface on an upper surface of the first layer and on an upper surface of the second layer; a first hole formed through the first layer; a second hole formed through the second layer, the first hole and the second hole being at least partially aligned to form a portion of a vacuum chamber; a first opening formed on the mold surface, the first opening extending from the mold surface to the vacuum chamber; and a second opening connected to the vacuum chamber, the second opening being configured to connect the vacuum chamber to a vacuum pump.

2 . The part of claim 1 , wherein the second opening extends from a bottom surface of the part to the vacuum chamber.

3 . The part of claim 1 , wherein the first opening is formed in a shape of a slot, the slot having a length that is greater than a width of the slot.

4 . The part of claim 1 , wherein the first layer includes a wall extending from the first opening to the mold surface.

5 . The part of claim 1 , wherein the vacuum chamber is a first vacuum chamber and the part includes a second vacuum chamber, the second vacuum chamber extending through the first layer and through the second layer.

6 . The part of claim 1 , further including:
a third hole formed in the first layer; and a fourth hole formed in the second layer, the third hole being at least partially aligned with the fourth hole.

7 . The part of claim 1 , further including:
a third hole formed in the first layer; and a fourth hole formed in the second layer, the third hole being at least partially aligned with the fourth hole, wherein the first hole and the second hole each have a first shape and the third hole and the fourth hole each have a second shape that is different than the first shape.

8 . The part of claim 1 , further including:
a third hole formed in the first layer; and a fourth hole formed in the second layer, the third hole being at least partially aligned with the fourth hole to form a coolant channel.

9 . The part of claim 1 , wherein the first layer and the second layer are stacked along a stacking direction, the stacking direction being a horizontal direction.

10 . The part of claim 1 , wherein the mold surface is continuous along the upper surface of the first layer and the upper surface of the second layer.

11 . A part for forming a mold, the part comprising:
a plurality of layers, including a first layer and a second layer, the first layer adjacent to the second layer to form a work surface on an upper surface of the first layer and an upper surface of the second layer; a first hole formed in the first layer; a second hole formed in the second layer, the second hole at least partially aligned with the first hole, the first hole and second hole together forming a coolant channel; a third hole formed in the first layer; and a fourth hole formed in the second layer, the third hole at least partially aligned with the fourth hole, the third hole and the fourth hole together forming a vacuum chamber, the vacuum chamber fluidly isolated from the coolant channel.

12 . The part of claim 11 , further including:
a second coolant channel extending through the first layer and the second layer.

13 . The part of claim 11 , further including:
a second coolant channel extending through the first layer and the second layer, the second coolant channel spaced apart from the coolant channel.

14 . The part of claim 11 , wherein the work surface is continuous along the upper surface of the first layer and the upper surface of the second layer.

15 . The part of claim 11 , wherein the vacuum chamber is a first vacuum chamber and the part includes a second vacuum chamber, the second vacuum chamber extending through the first layer and through the second layer.

16 . The part of claim 11 , further including:
an opening extending from a bottom surface of the part to the vacuum chamber, the opening being configured to connect the vacuum chamber to a vacuum pump.

17 . The part of claim 11 , wherein the first hole and the second hole form a horizontally-extending portion of the coolant channel, the coolant channel having a downward-facing opening.

18 . The part of claim 11 , wherein the coolant channel includes at least one downward-facing opening formed in the first layer, and wherein the at least one downward-facing opening providing access to the coolant channel for circulation of coolant.

19 . The part of claim 11 , wherein the coolant channel extends from an entrance positioned at a first end of the work surface to an exit positioned at an opposite end of the work surface.

20 . The part of claim 11 , further including:
a wall separating the coolant channel from the work surface and separating the vacuum chamber from the work surface.

Assignees

• Thermwood Corp

Inventors

• Susnjara Kenneth J

Classifications

• B29K2905/00

  Use of metals, their alloys or their compounds, as mould material · CPC title

• B29C33/10

  with incorporated venting means · CPC title

• B29C33/04

  using liquids, gas or steam {(tyre moulds with incorporated heating or cooling means using liquids, gas or steam B29D30/0601)} · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title