Abstract: An injection molding method for forming an article having a receptacle with a coating on an interior surface includes providing an injection molding tool with at least one cavity in one part and at least one core pin projecting from a second part having an outside surface. The core pin is sized to fit within the cavity with a clearance thereby defining a cavity space. The injection molding tool has an open position wherein the core pin is withdrawn from the cavity and a closed position wherein the core pin is disposed within the cavity for defining the cavity space. The method further sequentially then includes moving the injection molding tool to the open position and applying a coating of a coating material to the outside surface of the core pin. The method further includes moving the injection molding tool to the closed position.

Abstract: An electronic part, which has a complicated internal configuration and has a movable part rotatably and movably accommodated therein, is integrally molded without dividing the configuration into a plurality of sections to carry out a number of molding operations for separate sections of the electronic part, thereby reducing the cost and enhancing the quality of the electronic part.

Abstract: An implant having an integrally-textured, hemocompatible blood-contacting surface and a method for producing the same is provided. The implantable device can include a device body having a textured surface and a predefined complex shape, such as a bladder or a generally U-shaped conduit. The device body can be composed of a first device material, and the textured surface can be formed of a second device material on the obverse side of the device. The textured surface can have multiple, blood-compatible structures integrally formed thereon. The structures can be fibrils that are suitable for a generally uniform biological layer to be established thereupon.

Abstract: The invention relates to a material of a three-dimensional framework of supporting, trabecular structures encompassing cavities which are connected with one another and which can be predeterminedly adjusted. The material is obtainable by forming the framework around the shaped bodies serving as space retainers for the cavities and subsequently removing the shaped bodies. The material according to the invention can be used for example as a implant or as a filter.

Abstract: A strong, dimensionally stable object, such as a tooling fixture, is produced by providing a three dimensional, rapid free form fabricated object having a hollow internal cavity and flowing a strengthening material, such as an epoxy resin, into the internal cavity.

Abstract: A method for making a molded refractory article including the steps of providing a mold including a master pattern, the mold and master pattern defining a mold cavity; filling the mold cavity with a mixture comprising refractory particles and a heat fugitive binder; placing the assembly of the mold, master pattern and mixture in a furnace; curing the mixture; separating the mold and master pattern from the cured mixture; removing the binder to form a porous structure, sintering the porous structure to provide a porous refractory article and infiltrating the porous refractory article with a filler metal.

Abstract: A golf club shaft manufacturing process for making a lightweight golf club shaft that is not uniformly tapered along its length by using standard table-rolling tools and equipment. The process consists generally of creating one or more hollow sleeves and securing them around the exterior of a mandrel, the sleeves having a length and an exterior shape equal to the desired dimensions of the non-tapered portions of the shaft. Graphite flags are then rolled around the mandrel and sleeve, shrink tape is applied and the entire assembly is placed in a curing oven to cure the graphite shaft. The curing temperature is less than the melting point of either the mandrel or sleeve. Once the shaft has been cured, the shrink tape is removed and the mandrel is extracted. The remaining shaft and sleeve assembly is heated to a temperature greater than the melting point of the sleeve material so that the sleeve is liquefied and can be poured out of the shaft. The cured shaft can then be cut, sanded and finished as desired.

Abstract: A process for manufacturing a golf-club head is disclosed comprising; shaping a fluid-removable core in the general form of the club head, placing a flexible inflatable bladder around the core, wrapping over the assembly of core and bladder at least one ply of fiber impregnated with a curable resin, placing the assembly of core, bladder, and impregnated fiber into a female mold, forming a cured part in the form of a golf-club head by inflating the bladder to force the plies against the inner surfaces of the mold and heating the mold to cure the resin, removing the cured part from the mold, disintegrating the fluid-removable core with a fluid sufficient to allow removal of the bladder from the interior of the cured part through a hole in the cured part, removing the bladder through the hole with any residues of the core within the bladder to form a hollow molded club head with a hollow interior essentially free from non-functional materials.

Abstract: The present invention is a process for making a nanochannel glass (NCG) rica, having the steps of: coating a face of an etched NCG with a replica material (with or without an intervening buffer layer), where the etched NCG face has a plurality of channels arranged in a desired pattern, to form a replica coating on the NCG conforming to the pattern; and removing the replica coating from the etched NCG. The present invention is also the replica made by this process.

Abstract: A method of injection molding ceramic or metal parts having an internal cavity or other complicated shape. A fugitive core is formed of a particulate and a first binder. The core is then suspended in a conventional injection molding cavity. The part is then injection molded by injecting a ceramic or metal powder mixed with a second binder while in a plastic state into the mold cavity and around the suspended core. Once the second different binder hardens or gels, the molded part together with the core are removed from the mold cavity. The molded part and core are then subject to a debinding process to debind the first binder to thereby remove the core. Because two different binders were used for the core and molding, the binder used to form the molded part remains unaffected when removing the core.

Abstract: A method is provided for forming a strippable or dissolvable release coating on the surface of substrate such as a flexible polymeric film or web. The release coating is subsequently coated with a layer of material and then dissolved in a solvent to release the layer. The release coating is made from a copolymer of methylmethacrylate and ethylacrylate or from a homopolymer of polyacrylic acid. Release coatings made of methylmethacrylate and ethylacrylate copolymers having glass transition temperatures of about 60.degree. C. or greater, or made of a ipolyacrylic acid homopolymer having a glass transition temperature of about 100.degree. C. or higher, are also provided. The release coatings provide excellent supporting substrates for the formation of an overcoated metallized layer, are readily strippable in acetone, and can be formed during an in-line process which begins with drawing a flexible film or web from a molten polymeric material.

Abstract: A method for fabricating a composite pressure vessel comprising layering up of an uncured carbon fiber fabric/resin prepreg on a mold. Thereupon an uncured insulating rubber is layered up and combined with the uncured carbon fiber fabric/resin prepreg by autoclaving. This method produces an insulator for a composite pressure vessel which insulator is an aspect of the present invention.

Abstract: A method for the manufacture of intravascular stents of bioresorbable material comprises the following steps:preparing a viscous solution of poly-.beta.-hydroxybutanoic acid as a bioresorbable polymeric material in a solvent,successively coating a male mold core with layers of the polymer solution in several steps by precipitation of the polymeric material by the solvent being evaporated and by the layer previously precipitated being dissolved at least partially for a homogeneous stent blank to build up,drawing the stent blank off the male mold core, andsubsequently treating the stent blank to finish the shaping of the stent.

Abstract: The present invention provides for a sign consisting of an alloy substrate encapsulated in a porcelain coating which can be selectively applied to different areas of the substrate. The coating provides a smooth transitional region on graphic indicia of the sign to make the sign impervious to vandalism, fire and dirt. There is also provided a process of selectively applying a second coat of porcelain to the existing coating to only those elevated portions elevated or Braille portions of the substrate.

Abstract: A method for bend forging an artistic metallic straight pipe, wherein, a die core made from a steel rope is placed in the pipe bore, and a filler with plastisol uniformly mixed up is then introduced into the pipe bore until it is saturated to form a solid straight pipe. The latter is placed in an upper and a lower bendable die housing each of which forms a trough, and both ends of the die housings are provided with latch holes. Polyurethane is poured into the troughs to envelop the straight pipe, many hard bracing stubs are buried in the top/bottom of the troughs after heating, to solidify the polyurethane, a flexible die set is formed. The external top and bottom surfaces of the upper and lower die housings are provided thereon with two laminated springs, so that when the die set is forged, action force can be uniformly distributed to render the straight pipe to be bending forged to have the desired bending curvature.

Abstract: A method for forming a ceramic mold comprises the step of placing a pattern having critical pattern surfaces in a flask having an open end. The critical pattern surfaces face upward toward the open end. Successive steps include adding a concentrated heat reversible gel solution to the flask to cover the critical pattern surfaces, and cooling the gel solution to form an elastic solid gel mold. The gel mold has critical gel mold surfaces inverse to the critical pattern surfaces. Further steps include removing the pattern from the elastic gel mold, casting a ceramic mold around the gel mold, and liquifying the gel mold to remove it from the ceramic mold. The ceramic mold has critical ceramic surfaces inverse to the critical gel mold surfaces, thereby accurately replicating the critical pattern surfaces.

Abstract: A method for preparing mimics of a wide variety of drugs and other biologlly active molecules using molecular imprinting techniques, and the mimics produced thereby, is disclosed. Specifically, the mimic is designed by: (i) polymerization of functional monomers around a known drug or biologically active molecule (the template) that exhibits a desired activity; (ii) removal of the template molecule; and then (iii) polymerization of a second class of monomers in the void left by the template, to provide a new organic molecule which exhibits one or more desired properties which are similar to that of the template.

Abstract: A method and apparatus for building three-dimensional objects having an internal structure, wherein the structure is discontinuous and is composed from a plurality of patterns and bridging patterns formed on a plurality of levels, wherein a bridging level and pattern reside between previous and subsequent levels from which the bridging pattern obtains at least a portion of its pattern. A portion of the bridging pattern is obtained from the pattern on the previous level and a portion of the bridging pattern is obtained from the pattern on the subsequent level.

Abstract: A method of fabricating complex hollow composite structures from laminates of fiber reinforced synthetic resins. The structures are fully monocoque tubes with no seams. The tubes are manufactured by wrapping a hollow semi-rigid inner mandrel made of thermoplastic material such as polystyrene or ABS (acrylonitrile-butadiene-styrene co-polymer) with layers of composite sheets. The sheets are made from high-strength fibers impregnated with thermosetting or thermoplastic resins.The laminated mandrel is placed in a mold, heated and inflated to a predetermined pressure. The pressure can range from 20-200 psig and even higher, while the curing temperature can range from 200.degree.-600.degree. F. The pressure generated by the expanding core produces a highly consolidated composite structure that has fewer voids, a more uniform thickness, and an increased fiber content compared to hollow composites made by other fabrication methods.

Abstract: A laminate molding method of fabricating a desired shape consisting of laminate layers having a first type layer in a completely solidified state, the method includes a first step of forming a second type layer on the first type layer, the first type layer having a viscosity larger than the second type layer, a second step of forming a slot groove in the second layer, the second type layer having first and second regions, a third step of printing a releaser on a predetermined region of the second type layer, a fourth step of forming a third type layer on the second type layer or on the first type layer, the second type having a viscosity larger than the third type layer, a fifth step of solidifying the third type layer to form the first type layer, and a sixth step of repeating the first, second, third, fourth, and fifth steps as desired.

Abstract: A ceramic component is manufactured rapidly using a mold made directly from a solid freeform manufacturing process. Solid freeform fabrication, or rapid prototyping, procedures are used to generate molds of materials that are soluble or otherwise fugitive. A gel casting suspension containing ceramic and emulsifying agents is poured into the cavity of the mold and caused to set. The mold is then removed by dissolution or heat treatment, leaving intact the gelcast part. Conventional procedures are then utilized to densify the gelcast component to the required final component. Time consuming and expensive machine tooling procedures are virtually eliminated. Ceramic components are generated rapidly in a cost effective manner.

Abstract: A mandrel is fitted with a molded sleeve of low-temperature alloy for forming a rigid bulge along the surface of the mandrel. The sleeve is shaped to define the internal surface of the shell at the bulge. After the mandrel has been so modified with the low-temperature alloy sleeve, it is wrapped with composite cloth containing any thermosetting resin. These resins heat to a known temperature, and permanently set when cured at the set temperature. The curing temperature of the prepreg cloth composite material is lower than the melting point of the low temperature alloy. After curing, the temperature in the curing oven is raised above the cure temperature until it reaches the melting point of the low-temperature alloy, and the alloy liquifies and drains out the drain passageways provided in the mandrel without melting the thermoset resin binder in the fiber cloth as well as leaving the bulge formed by the composite cloth in the shell without obstructing the removal of the mandrel.

Abstract: An implantable bone prosthesis, such as an acetabular shell, includes a bone engaging region that is made from a cast metal or metal alloy and an articulation surface that is formed of a ceramic material or a metal that is permanently attached to the metal bone engaging region. The bone engaging region of the prosthesis preferably includes a dampening mechanism to absorb some of the loading forces communicated to the acetabular cavity. The bone prosthesis is formed by a casting process from casting molds that are prepared using a three dimensional printing technique.

Abstract: Methods are provided for producing investment cast articles, such as orthopedic implants, or portions thereof, having at least a partially textured surface that is formed during casting of the article. In an exemplary method, a textured metal casting is produced by creating a heat destructible pattern and spraying the pattern with a texturing material to cause the texturing material to form a textured surface on at least a portion of the pattern. In another embodiment, a textured template is pressed against a heat softenable pattern to provide a textured pattern. With respect to each of these methods, a shell is the created around the textured pattern to form a mold, and the pattern is removed from the shell. Molten metal is introduced into the mold and allowed to harden, after which the mold is removed.

Abstract: A method for consolidating powdered material to near net shape and full density is provided. The method includes the steps of: mixing a particulate material with an organic or inorganic binder to form a mold material; shaping the mold material into a mold having a shape and including an external surface and an interior cavity and being of sufficient solidity to maintain its shape yet being compressible under pressure; filling the interior cavity with a powdered material to be consolidated; heating the mold with the powdered material therein to form a heated filled mold; applying pressure to the external surface of the mold sufficient to compress the mold material and transfer a pressurizing force to the powdered material within the mold cavity so as to consolidate the powder and form an article; and removing the article from the mold. In an alternative method, the mold material is made of a particulate material which is held in the shape of the mold by a vacuum.

Abstract: Methods are provided for producing investment cast articles, such as orthopedic implants, or portions thereof, having at least a partially textured surface that is formed during casting of the article. In an exemplary method, a textured metal casting is produced by creating a heat destructible pattern and spraying the pattern with a texturing material to cause the texturing material to form a textured surface on at least a portion of the pattern. In another embodiment, a textured template is pressed against a heat softenable pattern to provide a textured pattern. With respect to each of these methods, a shell is created around the textured pattern to form a mold, and the pattern is removed from the shell. Molten metal is introduced into the mold and allowed to harden, after which the mold is removed.

Abstract: The present invention provides an improved method for rapidly making an electrode for electrical discharge machining. According to the invention, a stereolithography process is used to make a cured resin model of the electrode and having a network of interconnected supporting members defining the shape of the electrode and leaving channels between the supporting members to drain away uncured resin from the model. After the model is fully cured and the uncured resin drained away, a slurry mixture of graphite and resin is infiltrated into the voids of the model. The resin is then heat cured so that the resin is burned away leaving the electrode of pure carbon. Alternatively, the graphite and resin mixture can be cured sufficiently to harden and then an electrically conductive metalized coating is applied on the outer surface.

Abstract: A composite socket member for use with a prosthetic appliance for a residual limb which comprises an outer socket which defines an inner cavity generally conforming to the outer surface of a residual limb, an inner socket which defines an inner cavity and being adapted to receive said residual limb, with said inner socket conforming to the shape of said outer socket and when nested within the cavity of said outer socket defines an air space between the inner surface of said outer socket and the outer surface of said inner socket and an inflatable bladder being disposed between the inner surface of said outer socket and the outer surface of said inner socket. The inner socket contains at least one flex area in its side wall at a preselected weight-bearing location whereby upon inflation of said bladder, pressure is applied by said bladder against said side wall at said preselected weight-bearing location of the residual limb to control the movement and rotation stability of said prosthetic appliance.

Abstract: In the manufacture of a shaped part, which consists of different materials and includes a support body and a cover, which covers the support body at least in part, economical and rational production can be achieved in which the following process steps are provided: at least one model version of the shaped part in the original size is made out of shapeable material, a cover mold is made by using a model version in its original size, a model version of the original size is cut down to the contour of the support body and is thus used as a model for producing a support body mold, by means of which the support body is produced, and the cover mold is filled with a filling, which constitutes the cover and can be subsequently solidified, into which the previously made support body is embedded, and which is then solidified.

Abstract: A method of fabricating a threaded micro-ceramic part, includes the steps of: forming a sacrificial fiber, having a melting temperature greater than the sintering temperature of the ceramic material to be used to mold the threaded micro-ceramic part; winding the sacrificial fiber about a sintered ceramic plug generally in the shape of the threaded micro-ceramic part with the winded fiber corresponding to threads; providing a green ceramic housing formed with a passage and placing the plug with the wound sacrificial fiber in the passage.

Abstract: Three-dimensional modeling method and apparatus for receiving information with respect to a three-dimensional object to be formed and for forming a three-dimensional physical object through the use of two building materials and a third filling material. The first building material is typically a photopolymer. The second building material has at least one of the following characteristics: elastomeric properties, engineering plastic thermoset properties, is suitable for lost wax casting, is impregnated with metallic materials, is impregnated with ceramic material, or is sinterable. The filling material is typically a support material to provide structural support to the model during building.

Abstract: A method of creating a hollow sphere within a chamber including the steps of depositing a coating on a conductive fluid spherical mass at zero gravity, solidifying the coating, and removing the interior conductive fluid mass from the sphere to form a hollow sphere. In alternate embodiments the hollow sphere can be formed from, or coated with, a polymer.

Abstract: A process for integrally molding an assembly having parts in a die lock situation, in a single modeling step, with the process steps of has the steps of providing a composite component with a predefined contour, molding a core fuel rail integrated with the composite component, connecting the core fuel rail to a main core structure, overmolding the combined core fuel rail and main core structure to form a finished assembly, removing and melting out the combined core fuel rail and main core structure and extracting the composite component to provide the finished assembly with a substantially accurate finish. The core fuel rails and injector pockets are molded together with the main manifold body in a single step although the injector pockets are in a die lock situation relative to the main manifold body. The interior surfaces of the injector pockets molded using the present invention have a substantially accurate finish.

Abstract: Plural non-pneumatic (NPTs) are unitarily fitted, side-by-side, on a wheel rim, forming a multiple NPT (MNPT) to carry a load by sharing the load between the side-by-side NPTs. By "unitarily" is meant that the NPTs are fitted to the rim as a whole, without cutting or sectioning. With this construction, a MNPT is provided; with characteristics which are surprisingly better than those attributable to a single NPT having the same or a different outer hoop diameter but the same mass of resin as the plural NPTs. The NPTs may be formed as rings, then by heat-distending them, unitarily post-fitted to the surface of an adhesively prepped wheel rim, for operation at relatively low torque; alternatively, and more preferably the NPTs are cast or otherwise thermoformed, as for example by injection molding, onto the wheel rim and self-adhesively autogenously secured, so as to provide the plural NPTs integrally bonded to the wheel rim.

Abstract: A method making an affixation member including a body for affixation to a surface of a structure and means for fastening the body to the surface. The fastening means including an interengaging fastener member which has a base secured to the body and a plurality of headed stems arranged on the base. The fastening means is formed by flowing molten material into a base mold, a destructible stem mold and a head mold. The base mold and head mold are separated, and the destructible stem mold and the molded interengaging fastener member are placed within a cavity of a body mold. An affixation member fixedly supporting the interengaging fastener member is molded in the cavity of the body mold. The body mold is separated from the molded affixation member, and the stem mold is destructibly removed from the interengaging fastener member fixedly supported on the molded affixation member.

Abstract: A structural prototype of the component part is made by first creating a model of the part which is of cured resin and has a network of interconnected supporting members defining the shape of the part and leaving channels between the supporting members to drain away uncured resin from the model. A hardenable structural material is infiltrated into the channels of the model and cured so that the resin model has become reinforced to provide a structural model of the component part. The hardenable structural material may be a mixture of powdered graphite and resin which is cured by heat. The heat may be sufficient to both cure the hardenable structure material and burn away the cured resin of the model so that the component part is then comprised of the hardened structural material having a network of channels therein where the cured resin of the model has been burned away. The model can then be further strengthened by filling the network of channels with a suitable hardenable material.

Abstract: A method of manufacturing a hollow body such as a golf club head, having an external hollow body of molded thermal plastic material and an insert in the hollow by which it is possible to adjust the position of the center of gravity and the weight of the hollow body. An insert which is to remain within the hollow body is overmolded with a soft fusible metal to define with the insert a shape for the interior hollow of the hollow body. The hollow body of plastic material is overmolded over the combination of the insert and the overmolded core. The insert is then melted without melting the hollow body around it, and the melted insert material is removed from within the hollow body. For holding the insert and/or the fusible material core in place during the overmolding, either the insert is so shaped or a pin passes through the overmolded region defining an opening in the molded body through which the fusible material may be removed later, and that opening may be plugged.

Abstract: A moldable composition suitable for use as a pattern core material for investment casting. The composition comprises a water-soluble continuous phase organic material and a water-soluble fluorescing dye dispersed through the continuous phase organic material. Related disposable thermoplastic patterns and methods are also disclosed.

Abstract: A method of making a mold from a model is disclosed. A mold carrier is formed having an aperture therein. The aperture has a configuration generally corresponding to the shape of the model. The model is positioned within the aperture such that a space is created between the outer peripheral surface of the aperture and the outer peripheral surface of the model. A resilient first material in its liquid state is poured into the space such that the first material substantially covers the outer peripheral surface of the model. The resilient first material is allowed to solidify in the space such that a resilient mold insert is formed. The mold insert forms an impression of the outer peripheral surface of the model and is disposed along the inner peripheral surface of the aperture. The model is removed from the resilient mold insert. A second material in its liquid state is poured into the aperture of the mold carrier with the resilient mold insert disposed along the inner peripheral surface of the aperture.

Abstract: This invention relates to a continuous flow process of mold making or die making using a reusable bondable mixture substance to make selected finished products.

Abstract: A method of making microstructure bodies of plastic material. A microstructured plate-like base body which is made by any known molding procedure and which has a first side serving as a first reference plane and a second side which has plastic microstructures projecting therefrom is covered at its second side with a material layer that engages the microstructures, whereupon the material layer is machined to provide a second reference surface parallel to the first reference surface and the base body is then machined parallel to the second reference surface to expose the microstructures projecting therefrom and the material layer is finally removed selectively with respect to the plastic material to release the microstructured bodies.

Abstract: An elastic layer is formed stably of constant shape without cutting of surface thereof and without difficult processing to make an internal surface of hollow in a mold into an off-right-circular cylinder shape. A matrix 1 is produced by shaping a periphery of rod material into an inverted crown shape of off-right-circular cylinder. Annular reinforcements 2, 3 are fixed on the both ends of inverted crown portion of matrix 1. The matrix 1 with the reinforcements 2, 3 is dipped in an electrolytic solution 5a, so that a nickel alloy is deposited over a surface of matrix 1 by electroforming to obtain a mold 4. The mold 4 is cut outside the reinforcements 2, 3 and a hollow for dissolution removal is perforated along the axis of matrix 1. The mold 4 is dipped in a corrosive solution which can dissolve only the matrix 1, so that only the matrix 1 is dissolved to remove away from the mold 4. The remaining mold 4 will have a hollow of inverted crown therein.

Abstract: A molded article is prepared by forming a glass core, treating the glass core to induce residual stresses therein, inserting the core into a mold, injecting resin into the mold, curing the resin, fracturing the core to produce glass particles, and removing the glass particles from the molded article.

Abstract: A molded article is prepared by forming a core of glass beads secured together with a binder, inserting the core into a mold, injecting resin into the mold, curing the resin, solubilizing the binder to detach the glass beads from one another, and removing the glass beads from the molded article.

Abstract: An improved manufacturing process is provided for surface protective striking tools such as hammers and mallets. An elongate hollow core is fitted with impact heads at opposite ends thereof and filled with a flowable filler material such as small steel pellets prior to placement of the core into a mold cavity for injection mold formation of an outer encasement. During the molding step, the filler material provides a substantially rigid structural backstop which enables a core of lightweight construction to withstand typical injection molding parameters. The molded outer encasement ensheathes a skirt portion of the impact heads and any exposed portion of the core member to bind the impact heads to the core member. The molded outer encasement does not extend over an impact face of each impact head. A handle may also be molded with the outer encasement. A striking tool thus formed is removed from the mold, and some or all of the filler material is drained from the core through an open port.

Abstract: Making a tire mold by spraying molten atomized metal on a model to form a metal shell and then reinforcing the shell with a resin backing to form a mold segment for the tire mold. Modular shoe container assemblies have replaceable backing members for making different size molds and flat plate spacers for providing different thicknesses of the mold segment. In one embodiment a slide block is used for one side of the cavity whereby a sole plate is eliminated.

Abstract: The present invention relates to an improved pinless connector for use in microelectronics comprising an improved elastomer resin of polysiloxane and filler.

Abstract: A method of making a mold from a model is disclosed. A mold carrier is formed having an aperture therein. The aperture has a configuration generally corresponding to the shape of the model. The model is positioned within the aperture such that a space is created between the outer peripheral surface of the aperture and the outer peripheral surface of the model. A resilient first material in its liquid state is poured into the space such that the first material substantially covers the outer peripheral surface of the model. The resilient first material is allowed to solidify in the space such that a resilient mold insert is formed. The mold insert forms an impression of the outer peripheral surface of the model and is disposed along the inner peripheral surface of the aperture. The model is removed from the resilient mold insert. A second material in its liquid state is poured into the aperture of the mold carrier with the resilient mold insert disposed along the inner peripheral surface of the aperture.

Abstract: A core ring assembly for use in production of a plastic injection-molded component is formed by injecting molten metal alloy into core dies to produce two intricately shaped ring type elements--one male, one female. Removing the male and female ring elements from the core dies and combining the two elements in an assembly machine to form a uniform, geometrically symmetrical, integral core ring assembly. The core ring assembly is transported to a plastic molding machine for overmolding the core ring assembly with either thermosetting or thermoplastic material. Then, the core assembly is melted out from the plastic component in a hot oil bath or induction melt-out, and the molten alloy recovered thereby is returned to a molten metal alloy tank for reuse.

Abstract: A method of removing a core from a molded product in which the core is formed of a particulate inert material, such as .[.sand-bound.]. .Iadd.sand, bound .Iaddend.together by a cured binder of a water soluble carbohydrate alone or mixed with a silicate is disclosed. The silicate is preferably an alkali earth metal silicate, preferably sodium silicate, and the carbohydrate is preferably a saccharide or starch. The binder is cured by heat. The core and molded product are exposed to water, preferably heated water in a bath or steam, to rapidly disintegrate the core and remove it from the molded product.