Abstract: Processes and devices for dental restorations employ molding tools that isolate individual tooth surfaces onto which dental composite material is to be applied and cured into individual cavities to prevent bonding of adjacent teeth. The processes and tools utilize matrix separators between teeth and a molding tool having matrix guide pockets that receive edges of the matrix separators to define the individual cavities.

Abstract: The invention is directed to a casting process to make a metal 3D product by performing the following steps, (a) providing a form negative mould of the 3D product comprising of a plastic sheet which sheet defines at its inner side a hollow space corresponding with at least the shape of one or more of the 3D products by thermoforming using a master mould, (b) applying a layer of refractory material on the exterior of the plastic sheet of the mould to obtain a ceramic mould having a hollow space, (c) pouring molten metal into the hollow space of the ceramic mould and allowing the metal to solidify, and. (d) removing the layer of refractory material to obtain the metal 3D product.

Abstract: A method to manufacture reticulated metal foam includes coating a precursor in a molten wax to increase ligament thickness; and investment coating the molten wax coated precursor with a ceramic plaster.

Abstract: A method to manufacture reticulated metal foam includes coating a precursor in a molten wax to increase ligament thickness; and investment coating the molten wax coated precursor with a ceramic plaster.

Abstract: A core-in-a-core casting method and hybrid core (40) for use in the method. An inner core (42) formed of process-inert particles disposed in a binder material is used as a mold for casting an outer core ((44) formed of particles that will sinter during a subsequent firing step. The inner core provides mechanical support for the outer core during the firing step, and during which the inner core devolves into compacted but unbonded particles that can be removed conveniently from the outer core following the firing step to reveal the fired hollow outer core (44).

Abstract: The pattern has a pattern material and a casting core combination. The pattern material has an airfoil. The casting core combination is at least partially embedded in the pattern material. The casting core combination comprises a metallic casting core and at least one additional casting core. The metallic casting core has opposite first and second faces. The metallic core and at least one additional casting core extend spanwise into the airfoil of the pattern material. In at least a portion of the pattern material outside the airfoil of the pattern material, the metallic casting core is bent transverse to the spanwise direction so as to at least partially surround an adjacent portion of the at least one additional casting core.

Abstract: The present invention is a novel sprue rod assembly for lost wax investment casting and its method of use. The sprue rod is reusable because it is made of material with a high melting point, such as metal, instead of wax. The sprue rod assembly also comprises a weight pull system, which causes the sprue rod to fall out of the investment mold when it is heated prior to dewaxing or early during dewaxing. The reusable sprue rod assembly reduces wasted wax, increases the efficiency of dewaxing and decreases flaws from the expansion of trapped wax during dewaxing. In addition, the sprue rods can be stacked to create the desired length.

Abstract: A system and method for dewaxing is provided. The system includes a ceramic shell mold having a wall. Water is present within the wall of the ceramic shell mold. A wax pattern assembly is located within the ceramic shell mold. A heat source is configured for heating at least a portion of the wall of the ceramic shell mold in order to convert at least a portion of the water within the wall of the ceramic shell mold into steam for use in melting at least a portion of the wax pattern.

Abstract: The invention relates to a method for the production of a pattern for precision casting representation of turbine component comprising at least one cavity, whereby the prepared pattern comprises at least one core and an outer contour pattern, at least partly enclosing the core and at least partly defining the outer contour of the turbine component. The core is made from a hardening core material, which hardens during the course of the method and the outer contour pattern is made from a combustible or fusible material. The outer contour model is first produced with at least one cavity corresponding to the at least one cavity of the turbine component and subsequently, in order to form the at least one care, the hardening core material is introduced into the at least one cavity and hardened.

Abstract: A method for producing dental restoration components includes filling a retort cylinder of a retort system with a forming mass, the retort cylinder being at least partially encircled by a charging body, and hardening the forming mass. After the hardening of the forming mass, the retort cylinder and the charging body are removed from the forming mass, thereby leaving behind a retort. Thereafter, with the assistance of a press blank apparatus, a press blank having an outer contour substantially corresponding to the outer contour of the charging body is pressed into the retort.

Abstract: A lost wax molding system has a re-usable, collapsible, chain-linked mesh exoskeleton, one or more inserts to be placed within the interior surface of the mesh exoskeleton to exert outward pressure on the mesh exoskeleton thereby creating a pre-formed, rigid, three-dimensional shape, a waterproof sleeve sized to cover the outer surface of the three-dimensional shape, and a base sized to seal said waterproof sleeve forming an investment mold container.

Abstract: An apparatus and method to delay the application of pressure on a molten metal front to equalize a pressure gradient present at the molten metal front during pressurized lost foam casting processes, or other pressurized casting processes. A pressure equalization member is placed over a pouring cup to divert the direct application of pressure to molten metal present in the pouring cup. The pressure equalization member allows for increased pressurization rates in such processes, facilitating interdendritic feeding while reducing microporosity and metal penetration defects.

Abstract: The application relates to a foamable copolymer resin and a process for preparing the same, which comprises firstly adding an organic peroxide initiator, a modifying aid and a foaming agent to a mixed monomers of methyl methacrylate and styrene so as to constitute a homogenous mixture; at the same tine charging a deionized water into a polymerization reactor and adding a dispersant hydroxy ethyl cellulose or hydroxylpropyl cellulose ether with stirring to produce a homogenous mixture, then sealing the reactor and introducing N2 gas to purge the reactor before the above homogenous monomer mixture is added; after the completion of the reaction the residue is washed with water and dewatered and dried, obtaining foamable pellets.

Abstract: A fingerprint jewelry includes any jewelry with a person's fingerprints cast in relief onto its surface. It is made by pressing a finger on a sheet of pliable wax medium to imprint it with fingerprints in relief. In a first embodiment, the wax medium is comprised of a soft wax medium soft enough to be imprinted at room temperature. In a second embodiment, the wax medium is comprised of a soft wax medium supported on a hard wax medium. The imprinted wax medium is positioned in a hollow form. A mold is created around the wax medium by pouring a mold material into the hollow form. An oven is used to harden the mold material and melt away the wax to leave a mold cavity. Molten precious metal is cast into the mold cavity with a casting machine to produce a casting with the fingerprints in relief. The casting is freed by breaking the mold. Additional work may be performed on the casting to produce a finished piece of jewelry.

Abstract: Copolymers are formed by suspension polymerization of monomers, including one or more styrenic monomers, and methyl methacrylate. The polymerization can be carried out in the presence of one or more blowing agents, producing polymers that can be expanded. The methods are useful, for example, in forming expandable polymeric particles. The expandable polymer particles are useful in processes such as forming patterns for lost foam molding techniques.

Abstract: Copolymers are formed by suspension polymerization of monomers, including one or more styrenic monomers, and one or more acrylic monomers. The monomers can be polymerized in the presence of polymeric seeds. The polymerization can be carried out in the presence of one or more blowing agents, producing polymers that can be expanded. The methods are useful, for example, in forming expandable polymeric particles. The expandable polymer particles are useful in processes such as forming patterns for lost foam molding techniques.

Abstract: The invention relates to a camshaft made of cast steel having an inner cavity with a cylindrical inner shape, especially a profiled cylindrical inner shape produced rationally according to a lost-foam casting method known per se. A steel camshaft thus produced exhibits a long service life and can withstand extremely high hertzian surface pressures on its bearing surfaces without any damages.

Abstract: A method of manufacturing a turbocharger including a housing with a compressor housing portion, turbine housing portion, and a connecting portion is such that an appropriate attitude setting for various portions is preselected, and the housing is then manufactured using a casting technique. The geometry of the connecting portion is circular and concentric with respect to a common center line passing through all three portions.

Abstract: A casting includes a heat transfer surface having a plurality of cavities. The plurality of cavities include a density of at least about 25 cavities per square centimeter to about 1,100 cavities per square centimeter resulting in increased surface area and therefore enhanced heat transfer capability. Also disclosed is a mold for forming a pattern for molding the casting. The mold includes a surface defining a portion of a chamber to which are attached a plurality of particles having an average particle size in a range of about 300 microns to about 2,000 microns.

Abstract: Copolymers are formed by suspension polymerization of monomers, including one or more styrenic monomers, and one or more acrylic monomers. The monomers can be polymerized in the presence of polymeric seeds. The polymerization can be carried out in the presence of one or more blowing agents, producing polymers that can be expanded. The methods are useful, for example, in forming expandable polymeric particles. The expandable polymer particles are useful in processes such as forming patterns for lost foam molding techniques.

Abstract: A riser sleeve has a sleeve body and an evaporative pattern fit into the sleeve body to pass through a side wall thereof. The evaporative pattern is shaped to enable the casting, integrally with the riser cast by the sleeve body, of a projecting portion capable of receiving a wedge blade of an openable wedge blade type riser breaker. Even a top riser can therefore be broken off of the main casting at a neck portion by an opening force applied to the wedge blades of the riser breaker without the use of a special jig.

Abstract: A vent-forming apparatus for use in metal casting comprises a gas-permeable membrane with a lead-in tube attached to one surface and a breather tube attached to the opposite surface. The vent-forming apparatus may be used to create independent vents in the walls of shell-type molds used in the ceramic shell casting process for lost wax casting of ferrous and non-ferrous alloys. These vents exhaust gasses in the mold cavity to the atmosphere. The vent-forming apparatus also may be used in solid mold investment casting methods or in any other casting method in which venting is desirable or necessary.

Abstract: A casting includes a heat transfer surface having a plurality of cavities. The plurality of cavities include a density of at least about 25 cavities per square centimeter to about 1,100 cavities per square centimeter resulting in increased surface area and therefore enhanced heat transfer capability. Also disclosed is a mold for forming a pattern for molding the casting. The mold includes a surface defining a portion of a chamber to which are attached a plurality of particles having an average particle size in a range of about 300 microns to about 2,000 microns.

Abstract: This invention relates to a valve apparatus for use in metal casting and methods of its use. The valve apparatus according to this invention comprises a gas-permeable membrane with a lead-in tube attached to one surface and a breather tube attached to the opposite surface. The valve apparatus according to this invention may be used to create independent vents in the walls of shell-type molds used in the ceramic shell casting process for lost wax casting of ferrous and non-ferrous alloys. These vents exhaust gasses in the mold cavity to the atmosphere. The valve apparatus according to this invention also may be used in solid mold investment casting methods or in any other casting method in which venting is desirable or necessary.

Abstract: The method of lost foam casting uses a polystirene foam pattern molded from polystirene beads preexpanded from raw polystirene beads that have a raw bead diameter in the range of about 0.1 to about 0.6 millimeters and that include isopentane as a relatively slow diffusing blowing agent alone, or together with normal pentane as a relatively high diffusing blowing agent, the isopentane being present in an amount of at least about 40% by weight of the total blowing agent of the raw beads to significantly reduce post-molding dimensional pattern shrinkage and to render the molded patterns inherently more dimensionally stable. The patterns can be used directly in the lost foam casting of molten metal without the need for any intermediate pattern dimension-stabilizing treatment.

Abstract: A soluble wax core insert to be used in making a wax replica of a hollow metal jewelry ring has an inner round radius design and an arcuate portion having an arcuate extent of at least 140.degree.. The soluble wax core insert is formed by molding in a metal mold. Once formed, the core insert is placed in another metal mold and a plastiwax is introduced into and fills a cavity around the core insert. The plastiwax hardens and is removed from the latter mold with the core insert embedded in the hardened plastiwax article. The wax core insert is removed from the plastiwax article to yield a wax replica of the metal ring to be produced. The wax replica has an inner round radius design and is used to form a mold cavity in an investment material, which is used to cast the hollow metal jewelry ring.

Abstract: An improved method of lost foam casting of aluminum silicon alloys utilizing a pattern formed of an expandable polymeric foam having a decomposition temperature less than 300.degree. C., and a heat of decomposition less than 600 Joules per gram. The foam pattern preferably has a heat of fusion less than 60 Joules per gram and a bulk density in the range of one to four pounds per cubic foot. The lost foam casting procedure has particular use when casting hypereutectic aluminum silicon alloys containing from 16 to 30% silicon, and eliminates the "liquid styrene" defect which occurs when casting such alloys in a lost foam process utilizing conventional polystyrene foam patterns. When casting hypoeutectic aluminum-silicon alloys containing from 5% to 8% silicon, the method eliminates the "fold" defect.

Abstract: Assembling and adhering two component parts of a lost foam pattern comprises placing each of the two components on separate supports which initially face in the same direction, following which one of the supports and the component supported thereby are rotated through substantially 180.degree. to a position in which the two components confront and face one another. Each component has an exposed surface which confronts the other. An adhesive is applied to the exposed surface of one of the components, following which the supports are moved toward one another a distance sufficient to enable the confronting surfaces to engage and bond to one another. Thereafter the bonded components are separated from their respective supports and removed. The separate components are placed on their respective supports and the bonded components removed from such supports at a level which is ergonomically appropriate for the machine operator.

Abstract: A nail polish or nail polish/enamel composition is applied to imperfections, errors, distortions or porosities in the model. The composition is thus used to correct the model's shape. The composition can be added at room temperature, and avoids the need to utilize high temperatures in the process of building the model. The nail polish or nail polish/enamel compositions may be utilized to add jewelry design elements to the model.

Abstract: The apparatus includes a rubber base with two inlets, a two-chamber ceramic crucible with two identical outlets, and a model of the jewelry item with two sprues connected to two separate tree stems, with each sprue connected to a separate stem thus ensuring flow of different colors or different metals. Simultaneous casting of two different metal alloys of different colors in two separate chambers of the crucible is achieved by using a specially constructed two-head torch.

Abstract: Method of multi-color jewelry items production is based on a simultaneous casting of two metal alloys of different colors (yellow-red, white-yellow, etc.), as well as two different metals, with a purpose of obtaining jewelry art-works of high-quality and unique artistic impression. To serve that purpose, the following apparatus has been constructed: rubber base with two inlets, two-chamber ceramic crucible with two identical outlets, and a model of the jewelry item with two sprues connected to two separate tree stems, with each sprue connected to a separate stem thus ensuring flow of different colors or different metals. Simultaneous casting of two different metal alloys of different colors in two separate chambers of crucible is achieved by using a specially constructed two-head torch. Usage of this invention in the process of jewelry work casting ensures a unique natural effect of smooth transition from one color to another in a jewelry piece (ring, brooch, pendant, charm, etc.

Abstract: A spruing assembly for receiving investment material in the production of an investment mold for castings by the "lost wax" process which includes a hollow chamber to receive the investment material. Included within the chamber is one or more sprue for supporting the wax pattern(s) to be cast and one or more corresponding predetermined shaped reservoir(s) being slidably moveable up or down the sprue to create the heat center of the investment mold. Where a long span casting is to be produced all the reservoirs are connected to form a continuous reservoir or Feeder Bar which conforms to the curve of a long span dental arch. A base member is provided within the chamber for supporting the sprue.

Abstract: Disclosed herein is a one piece drive shaft housing comprising a casting including an outer surface having an upper end surface, a lower end surface, and an endless side surface extending between the upper and lower end surfaces, an internal cavity extending between the upper and lower end surfaces and adapted to receive a drive shaft and a clutch operated linkage, an internal exhaust gas passage extending between the upper and lower end surfaces and located in spaced relation to the cavity, an internal coolant supply passage extending between the upper and lower end surfaces, an internal idle exhaust passage including a series of expansion chambers and extending between the upper end surface and the endless side surface, and an internal coolant drainage passage extending between the upper and lower end surfaces in heat exchanging relation to the exhaust gas passage.

Abstract: A method of making an orthodontic appliance such as a bracket includes the step of forming a preform of molding material while a portion of the molding material is in contact with a textured portion of a web. The web is subsequently degraded by a thermal or solvent degrading process to leave a witness impression on the underside of the preform. The web optionally serves as a conveyor to move the preform from one processing area to another, and optionally has the appearance of a woven material such that the resulting appliance resembles a mesh base appliance having undercut regions.

Abstract: A method for casting a housing and insert assembly including a housing and a cast-in-place insert. The casting method comprises the steps of providing a prefabricated insert, surrounding the insert with an evaporable foam pattern to form a pattern and insert assembly, and utilizing the pattern and insert assembly in a lost foam casting process wherein the pattern is replaced by a material to form the housing and insert assembly.

Abstract: A lost foam pattern assembly comprising a crankcase section including first and second mounting surfaces, a right cylinder section which is fixed to the first mounting surface and which includes a primary locator, a left cylinder section which is fixed to the second mounting surface and which includes a primary locator, a transfer passage having an upper end located in the right cylinder section, and a transfer passage having an upper end located in the left cylinder section.

Abstract: The shape-dictating surfaces of the pattern are constituted by a thin self-supporting shell (4 & 5) of photocured polymer. The shell is produced by a laser controlled by a computer with reference to a design drawing. The inside of the shell is packed full of low melting-point modeling compound. The areas (6 & 7) of the pattern that do not dictate shape are demarcated by the low melting-point modeling compound.

Abstract: A cast tubular structure including an integral hose connection element formed thereon is produced by lost foam casting wherein a circular socket seat is formed on a pattern for a body portion of the cast tubular structure and a cylindrical pattern for the integral hose connection element is formed by a mold without vent openings on the mold surface in the area of the cylindrical pattern corresponding to the hose sealing surface of the cast tubular structure. The pattern sections are joined with the pattern section for the hose connection element sealing within the circular socket seal formed in the body portion of the cast structure.

Abstract: The pattern, composed of a polymeric material, is formed of three sections joined together by an adhesive along a pair of parallel parting lines. One parting line lies in a plane extending through the axis of an outlet to the engine block and through the axis of a sea water inlet, while the second parting line lies in a plane that extends through the axes of outlets leading to the exhaust manifolds of the V-engine. An inlet opening, through which coolant is received from the engine block, is located in one of the pattern sections and the axis of the inlet opening is normal to the parting lines.

Abstract: An evaporable foam pattern for casting a metal engine block for a two-cycle engine having a direct charge system. The pattern includes a block pattern section having a head end and a crankcase end and a plurality of cylinders extend between the ends. A transfer passage is associated with each cylinder and one end of each transfer passage communicates with the crank-case end of the block, while the opposite end of the transfer passage communicates with the cylinder adjacent the head end. The block pattern section is provided with a plurality of openings each of which provides communication between a transfer passage and the exterior and the openings are bordered by a generally planar surface. The pattern also includes a cover pattern section enclosing the openings in the first section.

Abstract: An evaporable foam pattern for casting a metal block for a two-cycle engine. The pattern includes a first pattern section formed of a polymeric material and defining at least one cylinder. The first pattern section has a plurality of elongated slots each of which extends through the section and communicate with a cylinder. Each slot is bordered by an external planar surface. The pattern also includes a group of second pattern sections each formed of polymeric material and having an inner portion extending within a slot and having a peripheral flange disposed in abutting relation with the surface bordering the slot. The abutting surfaces are joined together by an adhesive.

Abstract: Disclosed herein is a lost foam pattern assembly comprising a crankcase section including first and second planar surfaces intersecting at an angle defined therebetween, a port cylinder section fixed to the first surface of the crankcase section, and a starboard cylinder section fixed to the second surface of the crankcase section, which port and starboard cylinder sections are fixed to each other along a glue face located in a plane bisecting the angle.

Abstract: A pattern for use in casting a rotatable shaft, such as a crankshaft for an internal combustion engine. The pattern includes an evaporable foam pattern section composed of a material such as polystyrene and having a configuration conforming to the crankshaft to be cast. The evaporable foam pattern section includes a plurality of cranks connected by bearing areas, and tubular metal inserts formed of bearing quality steel are disposed around each bearing area and around the pin areas of the cranks. In the casting process, the pattern is placed in a mold and surrounded with a finely divided material such as sand. When molten ferrous metal is fed into contact with the pattern, the pattern will vaporize with the vapor passing into the interstices of the sand while the molten ferrous metal will occupy the void created by the vaporized foam to produce a cast crankshaft having bearing quality steel inserts at the bearing and pin areas.

Abstract: An evaporable foam pattern assembly for casting a housing for a rotary engine. The pattern assembly includes a central rotor chamber pattern section and a pair of end pattern sections which, in the cast engine, are mounted on either side of the central section. The cental pattern section is provided with a central chamber of epitrochoidal shape and the end sections are each formed with a central opening. The outer portion of each central opening is cylindrical in shape, while the inner portion is elliptical and separated from the outer portion by a relief groove. Each end pattern section is provided with an air passage that communicates through the relief groove with the elliptical opening, so that in the assembled cast engine, air introduced into the passage of one of the end sections flows into the rotor chamber of the central section and is discharged from the other end section.

Abstract: A foam pattern assembly for use in forming an engine block in a lost foam casting process, the pattern assembly comprising a base portion including a generally planar front mounting surface having therein a plurality of crankcase-defining cavities and a plurality of intake ports, and a rear mounting surface spaced from the front mounting surface, the base portion partially defining a plurality of transfer passages and a plurality of air intake passages each communicating between a respective one of the intake ports and a respective one of the transfer passages, and a cylinder portion including a generally planar front mounting surface mating with the rear mounting surface on the base portion, the cylinder portion partially defining the air intake passage and partially defining a plurality of cylinder bores each communcating with a respective one of the transfer passages.

Abstract: A lost foam pattern for an engine block includes a cylinder and an axially extending transfer passage defined by spaced side walls and an inner wall which is outwardly convex.

Abstract: A full mold for casting contains a plastic foam material lost pattern. The plastic foam material is substantially sulfur-free and can advantageously be used to provide iron alloy-based full-mold cast pieces of high quality.

Abstract: An evaporable foam pattern for casting a metal water-cooled exhaust manifold for an internal combustion engine. The assembled pattern is formed of an evaporable foam polymeric material, such as polystyrene, and includes an inner exhaust conduit composed of a generally upright body portion and a generally curved elbow portion. The body portion is provided with a plurality of inlet ports connected to the exhaust passages of a bank of cylinders, while the elbow portion defines a downwardly facing outlet. The pattern also includes an outer water jacket which is spaced from the exhaust conduit to provide a water passage therebetween. Both the exhaust conduit and the outer jacket are composed of two longitudinally split halves or sections having abutting edges, and the abutting edges are joined together by an adhesive. Spacing ribs interconnect the inner surface of the jacket and the outer surface of the exhaust conduit to space the sections apart.

Abstract: An evaporable foam pattern for casting a metal air induction manifold for an internal combustion engine. The pattern is formed from an evaporable foam material, such as polystyrene, and in the assembled condition the pattern is in the form of an elongated body member having a generally rectangular cross section. One end of the body member is enclosed by an end wall while the opposite end of the body member is open. One of the side walls of the body member is provided with a plurality of generally parallel slots which are elongated in a lateral direction with respect to the longitudinal axis of the body member. The pattern is composed of a pair of longitudinal pattern sections each being generally U-shaped in cross section and having abutting edges disposed on a parting line. An adhesive joins the abutting edges. The parting line between the pattern section splits the opening in the end of the body member and all of the slots are formed in one pattern section.

Abstract: A casting mold for the production of muffles which serve for the conversion of wax models to metal, with the casting mold having a funnel shaper (1) which consists of a disk-shaped base plate (4), at the circumference of which a side wall (5) which stands vertical to the base plate (4) runs, and a cone (6) arranged in the center of the base plate (4), pipe-shaped, muffle ring (2) partially inserted into the funnel shaper (1), with the outside wall of the muffle ring (2) resting against the inside circumference of the side wall (1) of the funnel shaper (1), a cylindrical ring (7) which is inserted on the side of the muffle ring (2) which faces the funnel shaper (1) and the central opening (8) of which surrounds the cone (6), and a blind funnel (3) provided on the side of the muffle ring (2) opposite the funnel shaper (3), whose funnel tip faces towards the cone (6 ) of the funnel shaper (1).