Abstract: Methods and apparatuses are disclosed to mold complex shapes using a cast mold technique. A catalyst-initiated urethane can be used for these complex shapes as there is little thickness restriction on any part dimension. Moreover, urethane, once chemically activated, can be poured into cast molds with various shapes. Due to the exothermic nature of urethane, when the curing chemical reaction takes place, metal molds can be fabricated from aluminum. Cast molds, made from aluminum, utilize elastomeric seals to account for coefficients of thermal expansion.

Abstract: The present invention provides a method and article involving a one-piece, unibody spindle liner having a tubular shape with an outside diameter and inside diameter that may be sized to fit virtually any spindle of a turning machine and to readily allow for the feeding therethrough of any size or shape of bar or tube stock. This invention provides that the axial centerline of the workpiece is maintained in concentric axial alignment with the working centerline of the turning machine to reduce wobble or “whip” of the stock during the machining process. The liner's inner bore and diameter is molded to match and allow for feeding of virtually any size and shape stock being turned, including but not limited to round, hex, square, and extruded. The inner bore is molded into the spindle liner along its entire length providing absolute support of the workpiece. The spindle liner also has a flanged mounting end to allow for the proper orientation and attachment to the spindle.