Abstract: A hybrid method of casting a metal product is disclosed. The method includes obtaining a product design, creating a mold insert based on the product design, creating a mold base based on the product design, assembling the mold insert with the mold base to form an assembled mold, casting the metal product with the assembled mold, and post-processing the metal product. In some embodiments, creating a mold insert includes generating printing instructions for a mold insert based on the product design and printing a mold insert configured to mate with a product mold (for example, a mold produced by traditional sand molding processes) based on the printing instructions.

Abstract: Improved processes for generating a mold configured for casting—are disclosed. An illustrative process comprises using one or more 3D sand printers to create interlocking modular pieces that, when assembled, form the mold. The interlocking modular pieces may be used to define cavities such as a pattern cavity, a sprue, a riser, a runner, or a vent. Additionally, the interlocking modular pieces may define cores to fit inside the pattern cavity.

Abstract: A hybrid method of casting a metal product disclosed. The method comprises obtaining a product design, creating a mold insert based on the product design, creating a mold base based on the product design, assembling the mold insert with the mold base to form an assembled mold, casting the metal product with the assembled mold, and post-processing the metal product. In some embodiments, creating a mold insert includes generating printing instructions for a mold insert based on the product design and printing a mold insert configured to mate with a product mold (for example, a mold produced by traditional sand molding processes) based on the printing instructions.