Abstract: A method of creating a sand mold for rapid casting, including the steps of determining a mold shape, providing a generally uniform thickness layer of sand, curing at least a portion of the layer of sand, machining the cured portions of the layer of sand based on the desired mold shape, and repeating the layer-forming, curing and machining steps until the sand mold is complete. Another aspect includes a machine for creating the sand mold having a build envelope defined by side walls, a movable build platform and at least one movable tool assembly, the movable tool assembly having a single or plurality of tools chosen from the group consisting of a sand dispenser, a sand leveling device, a curing device, and a machining device.

Abstract: A method of creating a sand mold for rapid casting, including the steps of determining a mold shape, providing a generally uniform thickness layer of sand, curing at least a portion of the layer of sand, machining the cured portions of the layer of sand based on the desired mold shape, and repeating the layer-forming, curing and machining steps until the sand mold is complete. Another aspect includes a machine for creating the sand mold having a build envelope defined by side walls, a movable build platform and at least one movable tool assembly, the movable tool assembly having a single or plurality of tools chosen from the group consisting of a sand dispenser, a sand leveling device, a curing device, and a machining device.

Abstract: A thermal erosion tester, comprising a rotating heated element, which is adapted to contact a sand specimen placed in the thermal erosion tester, a heating element to heat the rotating heated element, and a motor to drive rotation of the rotating heated element, wherein the rotating heated element is adapted to contact the sand specimen while the rotating heated element is rotating, causing erosion of the sand specimen, and a method of testing thermal erosion, and a method of testing erosion of a sand specimen when it is in contact with a heated element.

Abstract: A thermal distortion tester for testing thermal distortion of a sand specimen, comprising a gimbal to support the sand specimen, an actuator to raise and lower the sand specimen, and a hot surface, wherein the sand specimen is brought into contact with the hot surface at a pre-determined pressure or pressure profile. The temperature of the hot surface is maintained at a pre-determined temperature or temperature profile. The distortion of the sand specimen while applied to the hot surface is directly measured through measurement of the longitudinal movement of the gimbal, and radial distortion is measured by a micrometer camera. The temperature gradient of the sand specimen is also measured throughout the duration of the test. A method of using the same is also described herein.

Abstract: A composition is disclosed for a biodegradable, blendable plastic having improved tensile strength. It consists of starch, oxidized polyethylene, and polyethylene. The starch is included in an amount up to 50% by weight, the oxidized polyethylene up to 15% by weight, and the remaining amount is polyethylene. It is preferred that high molecular weight oxidized polyethylene be used and in the method of producing the composition, it is preferred that the blending of the components occur at a temperature range of 110.degree. C. to 200.degree. C.