Abstract: A method involves forming a core assembly. The forming includes molding a first ceramic core over a first refractory metal core to form a core subassembly. The subassembly is assembled to a second ceramic core.

Abstract: Dental appliances including multiple components and a system and method for constructing the same are disclosed herein. The dental components are designed to fit together to form the dental appliance. The components of the dental appliance are electronically modeled, printed, and pressed sequentially, separately, or as a unitary piece. Forming the dental appliance from multiple components enables each component of the dental appliance to be formed from a different material, each material having different features associated with it. In various embodiments, different materials have different colors, textures, opacities, and transformation factors associated with them. Furthermore, each component can be formed from multiple components. In some other embodiments, a support structure is designed and constructed in order to minimize deformation of a dental component during fabrication of the component.

Abstract: A blade outer air seal (BOAS) casting core has first and second end portions and a plurality of legs. Of these legs, first legs each have: a proximal end joining the first end portion; a main body portion; and a free distal portion. Second legs each have: a proximal end joining the second end portion; a main body portion; and a free distal portion.

Abstract: In a method for manufacturing a combination investment casting core, a plurality of cores are each formed by cutting a metallic sheet to define a first portion and a number of separate second portions linked by the first portion. The second portions are bent out of local alignment with the first portion. The first portions of the cores are assembled and secured to each other.

Abstract: A method is disclosed for molding a component with at least one microstructured functional element, which is configured intentionally with a defined structure, in relief, at a defined point on the surface of the component in order to specifically fulfill a function. The element has a characteristic dimension in the micrometer range in at least one spatial direction. The component is shaped from a substantially metallic material using a mould. At least one functional element is formed in a negative impression that is configured on the surface of the mould.

Abstract: A lost-wax cast impeller for a supercharger having no parting line on a hub surface and a blade surface in each space demarcated by pairs of long blades adjacent to each other and having excellent aerodynamic performance. A method of manufacturing the impeller involves forming a lost form pattern in substantially the same shape as the impeller, forming a mold by eliminating the lost form pattern after the lost form pattern is coated with a refractory, and pouring a molten metal in the mold for casting. In the molding step, lost material is injection-molded in a space demarcated by radially arranging, toward a center shaft, a plurality of slide molds having short blade-shaped bottomed groove parts and space shapes between the pairs of long blades adjacent to each other, and the slide molds are released by moving in the radial direction of the center shaft while rotating.

Abstract: A blade outer air seal (BOAS) casting core has first and second end portions and a plurality of legs. Of these legs, first legs each have: a first end joining the first end portion; a main body portion; and a second end. Second legs each have: a second end joining the second end portion; a main body portion; and a first portion. At least one of the second legs may have its first end joining the core first end portion and a plurality of apertures in the main body portion. Alternatively, at least one of the first legs may have its second end joining the core second end portion and a plurality of apertures in its main body portion.

Abstract: A method of casting a hollow hip prosthesis head comprises forming a wax pattern of a femoral head including two cores. The first is a central socket-forming core and the second a ceramic hollow-forming core. The wax pattern is coated with a ceramic slurry to form a shell in which core extensions are captivated. The wax is melted and evacuated and the shell is fired to form a mould. Metal is cast and, when cool, the shell and cores are removed and each aperture formed in the head by the hollow-forming core is sealed.

Abstract: A method for the production of a shell mould. The method comprises the sequential steps of: (i) dipping a preformed expendable pattern into a slurry of refractory particles and colloidal liquid binder whereby to form a coating layer on said pattern, (ii) depositing particles of refractory material onto said coating, and (iii) drying, steps (i) to (iii) being repeated as often as required to produce a shell mould having a primary coating layer and at least one secondary coating layer, characterised in that during at least one performance of step (ii) a gel-forming material is also deposited onto the coating layer formed in step (i).

Abstract: Solid free form fabrication techniques such as fused deposition modeling and three-dimensional printing are used to create a shell or die used in the manufacture of a dental restoration. Three-dimensional printing includes ink-jet printing a binder into selected areas of sequentially deposited layers of powder. Each layer is created by spreading a thin layer of powder over the surface of a powder bed. Instructions for each layer may be derived directly from a CAD representation of the restoration. The area to be printed is obtained by computing the area of intersection between the desired plane and the CAD representation of the object. All the layers required for an aesthetically sound shell can be deposited concurrently slice after slice and sintered/cured simultaneously.

Abstract: Investment-casting shells are disclosed that have at least one cluster of individual club-head casting molds for casting thin-walled, titanium alloy club-heads at high process yield and low material usage. The shells have respective combinations of cluster configuration and number, gating, and runners, as determined systematically. Some shell configurations include a cluster of at least ten casting molds for respective club-heads each (a) having a head-volume greater than 400 cm3, (b) defining at least one club-head wall having a thickness of less than 0.8 mm, and (c) defining at least one respective gate. The cluster is configured to produce a cast-ptoduct yield of greater than 80% at a material usage of less than 600 g, including process losses, per cast club-head. Also, at least one runner connects the gates together.

Abstract: Methods for rapid prototype casting metal components, wherein the metal components are cast in a secondary ceramic mold, the secondary ceramic mold is cast in a primary mold, and the primary mold is formed by rapid prototyping or rapid manufacturing. The secondary ceramic mold may comprise a one-piece integral shell and core(s), and the metal components may have at least one hollow portion or void therein, such as a hollow airfoil for a gas turbine engine.

Abstract: In precision casting of metallic components with very thin passage ducts, in particular turbine blades, by the lost-wax process, the ceramic core pins provided for forming the passage ducts are covered and stabilised via a low-melting reinforcing coat prior to injection of the wax material required for forming the wax pattern for the production of the ceramic casting mold, with the low-melting reinforcing coat being melted out together with the wax material after the casting mold has been formed on. The ceramic core pins are therefore not damaged during the production of the wax pattern, enabling very thin passage ducts to be formed in the precision casting process.

Abstract: A method of manufacture of a multilayer ceramic shell mould whereof at least one contact layer out of a wax master pattern or a part to be manufactured, or other similar material, includes a step of preparing a first slip containing ceramic particles and a binder; a step of dipping the master pattern in a first slip; a step of forming the contact layer, and a step of depositing sand particles particles onto the layer and drying the contact layer. The ceramic particles of the slip are mullite particles and the slip includes a texturing agent.

Abstract: A process and casting media composition for casting three-dimensional parts and sacrificial models from a class of foaming casting compounds, and creating the foaming casting compounds by combining a radiation activated catalyst that causes a phase change from liquid to solid in the material and a foaming agent. In an alternate embodiment the combination is of a cold foaming casting compound and a compound which contains a radiation activated catalyst that causes a phase change from liquid to solid in the material. A further embodiment combines a hot melt casting compound with a compound which contains a radiation activated catalyst that causes a phase change from liquid to solid in the material and a foaming or blowing agent.

Abstract: In one aspect, the present invention relates to a method of joining wax patterns for fabricating a golf club head. In one embodiment, the method has the step of providing a prefabricated first wax pattern and a prefabricated second wax pattern, embedding a joining portion of the second wax pattern into a recess portion of the first wax pattern, heating a flange formed on the recess portion to make the flange soften, and using a flattening tool to fold the flange over and into a chambered receiving portion on the second wax pattern such that the first wax pattern and second wax pattern are melted into a whole, joined surfaces of the first wax pattern and the second wax pattern are joined tightly with no gaps, and a single wax pattern if formed.

Abstract: A method of manufacture of a multilayer ceramic shell mould out of a master pattern includes the steps of dipping the master pattern in a first slip containing ceramic particles and a binder, depositing sand particles to form a contact layer, dipping the master pattern in a second slip containing ceramic particles and a binder, depositing sand particles to form an intermediate layer, dipping the master pattern in at least a third slip containing ceramic particles to form a reinforcing layer. The ceramic particles of the slips includes mullite, alumina, or a mixture of the two, whereas no layer contains any zircon.

Abstract: A combing method of wax patterns for fabricating a golf club head is provided in the present invention. Firstly, a golf club head is disassembled to two or more elements in advance, which are respectively formed into wax patterns. Next, a flange capable of being deformed upon being pressed under an appropriate temperature and a corresponding rabbet structure are predisposed on the two wax patterns, then, the temperature of the flange is raised to make it soften, and then, it is pressed into the rabbet by a flattening tool. By utilizing the softening characteristic of the wax upon being heated, the joint surfaces of the two wax patterns are melted into a single wax pattern. By the method, the two wax patterns are combined together without adding a medium there-between, and thereby forming a joint surface with no gaps.

Abstract: A wax pattern welding system and method for producing a pool of molten wax on an area of a surface of a wax component is provided. The wax pattern welding system includes a bar of heat conducting material and a heating element. The bar has a raised heating surface, which has a recessed area for retaining molten wax when the raised heating surface contacts the wax component, and a vent structure. The vent structure facilitates confining the pool of molten wax on an area of a surface of the wax component. In another embodiment, the pattern welding system includes an attachable plate of heat conducting material, which has a raised heating surface with a recessed area, and a vent structure. The attachable plate is configured to be fastened to the bar of heat conducting material.

Abstract: Pattern for the lost foam casting process including a pouring-basin-forming portion, a sprue-forming portion, a runner-forming portion, a gate-forming portion, and an inline-riser-forming portion. The runners formed by the pattern each have an inline riser through which melt flows between an inlet to and outlet from the riser during pouring, and in which melt is stored to feed the casting with melt during cooling/shrinkage of the casting. A sand dam surrounds the mouth of each gate and traps particulates from a liquid styrene layer that precedes the melt front in the riser.

Abstract: A method for manufacturing a mold (70), which comprises a step of forming a layer (31) of combustible powdery particles (32) around a wax mold (21), which is a lost pattern, a step of forming a film (51) of a ceramic precursor slurry (52) around the wax mold (21) having powdery particles (32) formed thereon, a step of subjecting the resultant product to a heat treatment, to thereby dewax the wax mold (21), and a step of firing the slurry film (51), to thereby burn and vanish the powdery particles (32) in the slurry film (51) and form a shell (71). The mold (70) has the shell (71) and a porous layer (74) formed on the surface (76) of the cavity of the shell. The mold can be suitably used for manufacturing a porous body (90) having a porous layer (94) on the surface thereof.

Abstract: An investment casting method involves producing a casting shell by applying a hardenable moist mixture to a sacrificial pattern. To hasten the hardening of the moist mixture to create the shell, a stucco coat is subsequently applied to the mixture. In some cases, the stucco coat comprises a drier mixture of the elements used in the moist mixture. The drier mixture preferably includes a material that alters the alkalinity of the underlying moist mixture. In some cases, the stucco coat also includes an amorphous mineral silicate. Once the shell is created, a molten metal is introduced into the shell to replace the sacrificial pattern, thereby producing a metal cast item.

Abstract: The present invention provides a manufacturing method of high precision titanium compressor wheel in which by removing pads attached on an entire surface entirely as a machining allowance in manufacturing process, dimensional accuracy at the time of manufacturing is intensified, and correction work of dynamic balance (rotation balance) is simplified or omitted so as to improve yield of products and suppress boosting of manufacturing cost. The outer peripheral face of a front cast boss portion of a cast titanium product is fixed with a chuck of lathe. A plurality of receiving plates projecting from the lathe are positioned between respective cast blades and front ends thereof are pressed against a disc-like large-diameter front end face formed on a rear half portion of a cast core portion. With a large-diameter front end face of the cast core portion and the outer peripheral face of the front cast boss portion as reference plane, the cast titanium product is held by the chuck and receiving plates and rotated.

Abstract: A fugitive pattern assembly is made by preforming one or more fugitive patterns of an article to be cast, placing the preformed patterns in an injection die, and injecting fluid gating material into the die to form gating connected to the patterns. The fugitive patterns are disposed in end-to-end and/or side-by-side relation and are interconnected by the gating.

Abstract: A process for manufacturing a blade of a turbomachine using the lost-wax moulding technique, where the blade includes a first central longitudinal cavity and at least one second longitudinal cavity together forming a cooling circuit and communicating with each other at one longitudinal end via a transverse channel. The process includes manufacturing first and second cores corresponding to the cavities, where the two cores each have an end portion, by which they are connected together by an assembly of the mortise and tenon type. The assembly of the two cores is then positioned in a shell mould and the metal poured into the mould.

Abstract: A method to recover wax from wax patterns used in investment casting using a lost wax technique without damaging incorporated ceramic cores is disclosed that includes subjecting the wax pattern to specific conditions. These conditions include chilling a casting tool including the wax pattern and ceramic cores such that a brittle transition temperature for the wax material is approached. Once chilled the wax pattern is subjected to brittle fracture release of the wax from the underlying ceramic cores without damage to those cores.

Abstract: A method for investment casting includes the steps of positioning a base plate relative to a die; molding a first material between the die and at least a first surface portion of the base plate; securing one or more patterns to the base plate, the one or more patterns comprising a second material; applying one or more coating layers over at least portions of the one or more patterns and at least a portion of the first material; substantially removing the first material through an interior receptacle of a manifold body and the second material through an exterior receptacle of the manifold body to leave one or more shells formed by the coating layers; removing said base plate; introducing molten metal to the one or more shells through the interior receptacle of the manifold body; permitting the molten metal to solidify; and destructively removing one or more investment casting molds.

Abstract: A process for the casting of metals includes the steps of providing a mold, delivering a molten metal into the mold, solidifying the molten metal, and removing at least a portion of the mold. The step of removing at least a portion of the mold begins before the step of solidifying the molten metal has been finished. An apparatus to deliver a solvent to a mold is also provided.

Abstract: A method is provided for removing a fugitive pattern, such as wax or other meltable pattern material, residing inside of a refractory mold by discharging condensable vapor such as steam inside the mold to contact and melt the pattern while an exterior of the mold is subjected to a non-condensing gas atmosphere such as air outside of the mold wherein the condensable vapor inside the mold and the atmosphere outside of the mold are at substantially the same pressure. Condensable vapor is condensed inside the mold where the vapor has contacted the pattern while the exterior of the mold remains free of condenate. The condensed vapor and melted pattern material are drained out of the mold. The condensed vapor can be discharged initially inside a hollow sprue of a fugitive pattern assembly to melt the sprue and then inside the mold to melt the patterns of the pattern assembly.

Abstract: The invention relates to a method for producing an effectively invisible gemstone setting by casting a wax model of the setting and inserting a flange or post between the stones and into the floor of the setting, or into a depression or aperture on the floor of the setting, in order to secure the stones placed in the wax model of the setting. The flange is shaped so that the majority of its body is hidden beneath the gemstones and so that a narrowed portion of the flange engages the sides or girdles of the gemstones. The upper portion of the flange has sloped sides and may reflect light to and from the crown of the gemstones mounted in the setting.

Abstract: The casting-mold material designed to manufacture casting molds used in casting high melting-point substances. The casting mold formed from a powder component containing magnesium oxide and aluminum oxide and a liquid component. The powder component additionally contains a calcium aluminate and an alkali fluoride or an earth alkali fluoride and the liquid component contains a polyelectrolyte and a basic component, the latter determining the liquid component pH value between 10 and 14. A fluid slip is prepared by mixing the powder and liquid components and is dried, hardened and sintered to produce a hollow mold.

Abstract: A manufacturing method for a hybrid one-piece design of a wax pattern of a golf club head includes the steps of: prefabricating a first wax pattern in a first molding assembly, the first wax pattern having a connecting portion; inserting the first wax pattern into a first mold cavity of a second molding assembly which has a configuration substantially corresponding to that of a first component of the golf club head; filling liquid wax into a second mold cavity of the second molding assembly which has a configuration substantially corresponding to that of a second component of the golf club head; and cooling the liquid wax in the second mold cavity to form a second wax pattern joined to the connecting portion of the first wax pattern.

Abstract: A method and apparatus is disclosed for forming a metal casting sprue for a lost foam casting process, the sprue formed in sand for receiving molten metal and directing the molten metal to a foam pattern in a mold cavity, wherein the sprue formation is facilitated by an insert having a plurality of apertures formed therein, the apertures facilitating an application of a coating to sand surrounding the insert prior to removal of the insert from the sand, and wherein the sprue facilitates a minimization of production costs and an optimization of material properties of the resultant casting.

Abstract: A method and apparatus for the lost pattern casting of metals employs an erodable mold including a particulate material and a binder. An erodable backing or coating may be used to support the erodable mold. After a molten metal casting is poured in the mold, the erodable backing and the mold are contacted with a solvent. This cools the molten metal so that it at least partially solidifies to form a casting. At least a part of the mold is removed. Also, the coating or backing may be removed.

Abstract: In a process for the assembly of wax trees, a wax runner is placed in a flat position, and a wax pattern is located adjacent to the wax runner. Both the wax pattern and the wax runner are heated and then placed in contact with one another where heated. Then the wax pattern and the wax runner are separated slightly to form a fillet weld between the wax pattern and the wax runner. An apparatus is also provided which, by robotics, brings a multiplicity of wax patterns to a wax runner and which automatically heats both the wax patterns and the wax runner before simultaneously pressing both the wax patterns and the wax runner together. Once a wax tree assembly is completed, a new wax runner replaces the wax runner that has been formed into a wax tree, and additional wax patterns are affixed in the same manner.

Abstract: An investment casting pattern is formed by forming a metallic first core element including at least one recess. The first core element is engaged to at least a mating one of an element of the die and a second core element. The recess serves to retain the first core element relative to the mating one. The die is assembled and a sacrificial material is introduced to the die to at least partially embed the first core element. The recess may be pre-formed prior to cutting the first core element from a larger sheet of material.

Abstract: A method and apparatus for the lost pattern casting of metals is disclosed. In the method, a pattern is formed from a material and a mold is formed around at least a portion of the pattern. The mold includes a particulate material and a binder. The pattern is removed from the mold and molten metal is delivered into the mold. The mold is contacted with the solvent and the molten metal is cooled such that it at least partially solidifies to form a casting. The step of cooling includes contacting a shell of solidifying metal around the molten metal with the solvent. An apparatus is also disclosed.

Abstract: The present invention is a method for casting a part having a complex shape or having a complex shape thereon. The method includes providing a pattern and securing at least one core to the pattern. A conformable material is located about the pattern and the core to create a complementary shape to the pattern and core in the conformable material. The pattern is removed and the core is left behind in the conformable material. The core leaves space, or an empty form, for a negative draw that cannot be formed in known casting methods. A mold is located adjacent the shaped, conformable material. A hardenable material is located between the mold and the shaped, conformable material and into the core. The hardenable material is allowed to harden and then it is removed. A cast part having a complex shape, or having a complex shape integrally formed with the part, results.

Abstract: There is provided a method or process for fabricating a hollow jewelry article which is hollowed or bored out. In accordance with this process, a metal ring model is prepared comprising a solid shank and a metal plate supported along the internal perimeter of the shank by means of a series of spokes extending from the shank. A first metal mold is produced from the metal ring model having the external shape of the jewelry article to be manufactured. From this mold, a wax model of the jewelry article is produced which is first filed down and then cast in order to form a metal model of a core insert; the core insert, like the ring model, has a plate disposed along the perimeter of the shank. This core insert is used to produce a second metal mold. This second mold may then be used repeatedly in order to form a soluble wax core insert model which is then inserted into the cavity of the first mold in order to define the hollow region of the article.

Abstract: A method of making an investment or lost foam casting assembly of a first part movable with respect to a second part includes making first and second separate wax or foam patterns of portions of the first part. Then, a third wax or foam pattern of the second part is made. Next, ceramic core pieces are made. At least one of the core pieces is mounted on the first pattern to form a subassembly. The subassembly is combined with the third pattern so that the core pieces maintain a separation between the third pattern and the first pattern. The first and second patterns are bonded together to trap the subassembly and to form a complete casting assembly.

Abstract: A piece of jewelry such a pendant is first cast in wax to provide a wax replica thereof. A gemstone is heated above the melting temperature of the wax replica and is pressed therein. Alternatively, the gemstone is positioned on the surface of the wax replica and pressure is applied to the gemstone to partially embed the gemstone in the wax replica surface at room temperature. The wax replica is then used to from the plaster of Paris mold wherein liquid metal is then poured within the plaster of Paris mold to replace the plaster to form the finished product.

Abstract: A connecting method for the wax patterns of the golf club head includes the steps of: prefabricating a first wax pattern and a second wax pattern, the first wax pattern providing with an engaging portion for engaging with the second wax pattern; employing a temperature difference to generate a manufacturing volume tolerance between the first wax pattern and the second wax pattern; combining the engaging portion of the first wax pattern with the second wax pattern; and cooling the first wax pattern to shrink the engaging portion so as to fittingly combine the first wax pattern with the second wax pattern.

Abstract: An apparatus for shelling an investment casting pattern has a tank containing a coating material. There are means for holding the pattern immersed in the coating material. There may be means for vibrating the pattern during immersion of the pattern and a vacuum source coupled to the tank to withdraw air from at least one headspace of the tank.

Abstract: A knife for heating the wax on the surface of a wax runner. The knife as a surface which is recessed in the center of the surface to permit melted wax to flow up into the recessed area and not flow away from the knife. Alternately, conformal heating surface which melts only that portion of the wax runner to which the pattern gate is affixed. Additionally an electrical circuit is provided which includes a heater and a temperature controller to limit the temperature at which wax is melted.

Abstract: An at least two step heating process is used to strengthen the shell of an investment casting mold including a refractory metal core. The first stage may occur under otherwise oxidizing conditions at a low enough temperature to avoid substantial core oxidation. The second stage may occur under essentially non-oxidizing conditions at a higher temperature.

Abstract: A wax runner is provided having risers along the edge of the surface which is melted to attach the wax gates of wax patterns to the wax runner. The risers prevent the flow of molten wax over the edge of the wax runner. In addition to the risers or separately, at least one locator extends from both ends of the wax runners, the locators are aligned with one another and assure a constant distance between the ends of the wax runner and the wax pattern being affixed to it. The locators further provide a fixed reference point.

Abstract: A process for the assembly of wax trees in which a wax runner is placed in a flat position and a wax pattern is located adjacent the wax runner. Both the wax runner pattern and the wax runner are heated and then are placed in contact with one another where heated. Then the wax pattern and the wax runner are separated slightly to form a fillet weld between the wax pattern and the wax runner. An apparatus is also provided which, by robotics, brings a multiplicity of wax patterns to a wax runner and which automatically heats both the wax patterns and the wax runner before simultaneously pressing both the wax pattern and the wax runner together. Once a wax tree assembly is completed a new wax runner replaces the wax runner that has been formed into a wax tree and additional wax runners are affixed in the same manner.

Abstract: A method of making an air boost device, wherein a compressor wheel incorporated therein is re-designed to permit die inserts (20), which occupy the air passage and define the blades (4, 5) during a process of forming a wax pattern (21) of a compressor wheel, to be pulled without being impeded by the blades. This modified blade design enables the automated production of wax patterns (21) using simplified tooling. These wax patterns (21) can be used in a large-scale investment casting process, and produce an economical cast titanium compressor wheel which performs aerodynamically at high boost pressure/RPM.

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: A sprue structure is specifically designed to facilitate the rapid filling of molded polystyrene patterns with molten metal. It comprises a down sprue and parallel columnar members that are connected to the down sprue. The flow of molten metal is initially downward through the first columnar member and then it reverses direction to flow upwardly through second and third columnar members so that the patterns to be cast receive molten metal as it travels upwardly through the second and third columnar members. This decreases the amount of pyrolyzation products that could otherwise flow through in-gates and into the patterns to be cast.