Abstract: A mold construction system is presented for use in additive manufacturing of a metal object. The system comprises: at least one mold provision device controllably operable to form one or more mold regions defining one or more respective object regions in a production layer, and configured to receive molten metal deposited to each object region; and a control system operating said at least one mold provision device in accordance with a predetermined building plan. The mold provision device is controllably operable, in accordance with said predetermined building plan, to create each mold region, in each production layer, with one or more metal-facing zones and one or more metal-nonadjacent zones around the metal-facing zone. Each metal-facing zone is configured to define a cavity forming the object region to receive the molten metal therein, and is configured with higher compressibility relatively to at least a sub-zone of the metal-nonadjacent zone.

Abstract: A mold construction system is presented for use in additive manufacturing of a metal object. The system comprises: at least one mold provision device controllably operable to form one or more mold regions defining one or more respective object regions in a production layer, and configured to receive molten metal deposited to each object region; and a control system operating said at least one mold provision device in accordance with a predetermined building plan. The mold provision device is controllably operable, in accordance with said predetermined building plan, to create each mold region, in each production layer, with one or more metal-facing zones and one or more metal-nonadjacent zones around the metal-facing zone. Each metal-facing zone is configured to define a cavity forming the object region to receive the molten metal therein, and is configured with higher compressibility relatively to at least a sub-zone of the metal-nonadjacent zone.

Abstract: A method for casting an object includes additively producing, by a casting system, multiple production layers, one currently-produced production layer after the other. For each currently-produced production layer, the method includes forming, by a mold system of the casting system, one or more mold-layers, providing, by a replaceable material provision system of the casting system, one or more replaceable material layers; and forming, by a molten metal processing of the casting system, one or more current object regions of the currently-produced production layer by providing molten metal that replaces the one or more replaceable material layers.

Abstract: A method and an apparatus for additive casting of parts is disclosed. The method may include: depositing, on a build table, a first portion of a mold, such that, the depositing may be performed layer by layer; pouring liquid substance into the first portion of the mold to form a first casted layer; solidifying at least a portion of the first casted layer; depositing a second portion of the mold, on top of the first portion of the mold; pouring the liquid substance into the second portion of the mold to form a second casted layer, on top of at least a portion of the first casted layer; and solidifying at least a portion of the second casted layer. The method may further include joining the first and second casted layers prior to the pouring of a third casted layer.

Abstract: A method for evaluating a three-dimensional (3D) model of a desired object based on casting system manufacturing constraints, the method may include (i) obtaining the 3D model of the desired object; wherein the 3D model comprises vertexes and angular information regarding angular relationships between the vertexes; (ii) virtually partitioning the 3D model to slices; (iii) generating a 3D model of a casting system-compliant object; wherein the generating comprises determining for each slice, based on casting system manufacturing constraints and on the 3D model of the desired object, (a) one or more mold regions associated with the slice, and (b) one or more object regions defined by the one or more mold regions, to be formed by molten metal processing; and (iv) responding to the generating of the 3D model of the casting system-compliant object

Abstract: A mold construction system is presented for use in additive manufacturing of a metal object. The system comprises: at least one mold provision device controllably operable to form one or more mold regions defining one or more respective object regions in a production layer, and configured to receive molten metal deposited to each object region; and a control system operating each mold provision device in accordance with a predetermined building plan. The mold provision device, in accordance with said predetermined building plan, creates each mold region of each production layer with at least one metal-facing zone configured to define at least one cavity forming the object region to receive the molten metal therein. The metal-facing zone comprises a predetermined arrangement of spaced-apart sites of relatively weak mechanical properties relative to spaces between said sites within said mold material.

Abstract: A mold construction system is presented for use in additive manufacturing of a metal object. The system comprises: at least one mold provision device controllably operable to form one or more mold regions defining one or more respective object regions in a production layer, and configured to receive molten metal deposited to each object region; and a control system operating said at least one mold provision device in accordance with a predetermined building plan. The mold provision device is controllably operable, in accordance with said predetermined building plan, to create each mold region, in each production layer, with one or more metal-facing zones and one or more metal-nonadjacent zones around the metal-facing zone. Each metal-facing zone is configured to define a cavity forming the object region to receive the molten metal therein, and is configured with higher compressibility relatively to at least a sub-zone of the metal-nonadjacent zone.

Abstract: A mold construction system is presented for use in additive manufacturing of a metal object. The system comprises: at least one mold provision device controllably operable to form one or more mold regions defining one or more respective metal object regions in a production layer; and a control system operating said at least one mold provision device in accordance with a predetermined building plan. The mold provision device operates, in accordance with said predetermined building plan, to create each mold regions by sequentially forming the following: a metal-facing zone defining a cavity forming the metal object region, and a metal-nonadjacent zone around the metal-facing zone. The metal-facing zone of the mold region is made of a ceramic-based material and is distinct from the metal-nonadjacent zone in at least one of material composition and mold deposition process parameters.

Abstract: A casting system for casting an object, wherein the casting system may include a mold system, a replaceable material provision system, and a molten metal processing system. The casting system may be configured to additively produce multiple production layers, one currently-produced production layer after the other. For each currently-produced production layer: (i) the mold system is configured to form one or more mold-layers, (ii) the replaceable material provision system is configured to provide one or more replaceable material layers; and (iii) the molten metal processing system is configured to form one or more current object regions of the currently-produced production layer by providing molten metal that replace the one or more replaceable material layers.

Abstract: A method and an apparatus for additive casting of parts is disclosed. The method may include: depositing, on a build table, a first portion of a mold, such that, the depositing may be performed layer by layer; pouring liquid substance into the first portion of the mold to form a first casted layer; solidifying at least a portion of the first casted layer; depositing a second portion of the mold, on top of the first portion of the mold; pouring the liquid substance into the second portion of the mold to form a second casted layer, on top of at least a portion of the first casted layer; and solidifying at least a portion of the second casted layer. The method may further include joining the first and second casted layers prior to the pouring of a third casted layer.

Abstract: A method and an apparatus for additive casting of parts is disclosed. The method may include: depositing, on a build table, a first portion of a mold, such that, the depositing may be performed layer by layer; pouring liquid substance into the first portion of the mold to form a first casted layer; solidifying at least a portion of the first casted layer; depositing a second portion of the mold, on top of the first portion of the mold; pouring the liquid substance into the second portion of the mold to form a second casted layer, on top of at least a portion of the first casted layer; and solidifying at least a portion of the second casted layer. The method may further include joining the first and second casted layers prior to the pouring of a third casted layer.

Abstract: A method and an apparatus for additive casting of parts is disclosed. The method may include: depositing, on a build table, a first portion of a mold, such that, the depositing may be performed layer by layer; pouring liquid substance into the first portion of the mold to form a first casted layer; solidifying at least a portion of the first casted layer; depositing a second portion of the mold, on top of the first portion of the mold; pouring the liquid substance into the second portion of the mold to form a second casted layer, on top of at least a portion of the first casted layer; and solidifying at least a portion of the second casted layer. The method may further include joining the first and second casted layers prior to the pouring of a third casted layer.