Abstract: The present invention provides methods to create a pattern part, and a subsequent mold core package, that can be used in the casting process to cast one or more die components having a near net-shape of the finished part. In this way, the present invention provides a cast part which greatly reduces the amount of finishing work that needs to be performed on the part after casting. Further, the present invention provides a method which involves less upfront stock material to cast the near net-shape of the desired die component part. The present invention accomplishes this by providing an efficient and effective automated method to determine where and how to add appropriate mechanical features to a design model part to produce a manufacturing model part in a CAD software program.

Abstract: The present invention provides methods to create a pattern part, and a subsequent mold core package, that can be used in the casting process to cast one or more die components having a near net-shape of the finished part. In this way, the present invention provides a cast part which greatly reduces the amount of finishing work that needs to be performed on the part after casting. Further, the present invention provides a method which involves less upfront stock material to cast the near net-shape of the desired die component part. The present invention accomplishes this by providing an efficient and effective automated method to determine where and how to add appropriate mechanical features to a design model part to produce a manufacturing model part in a CAD software program.