Abstract: A custom-fitting prosthetics liner is made without mixing silicone and without making a mold. A thermoformable liner is made by preparing a negative cast from a patient's residual limb, preparing a positive cast from the negative cast, and placing a thermoformable tubular liner over the positive cast. The positive cast and liner are heated in an oven for a predetermined time and temperature. Having acquired a new geometry, the cast and liner are removed from the oven and allowed to cool to room temperature. The liner is then removed from the cast. Alternatively the liner is heated, placed over the positive cast, cooled and removed. The interior surface of the liner conforms to the shape of the cast. The liner is elastic so that it returns to its new geometry when stretched and released. It therefore holds on to a residual limb even when the residual limb shrinks.

Abstract: A resin (61) as a material of a resin mold is injected in a second resin filling space (57) from a resin injection hole (51) provided in a second back surface reinforcing member (50). When the resin overflows from a resin overflow hole (52), the injection of the resin is stopped, followed by curing of the resin. During the operation of the resin filling step, since a downward load equivalent to a total of a weight of the resin injected in the second resin filling space and the injection pressure is applied to the master model (30), there is a possibility that the master model be deflected downwardly; however, in actual, since the back surface of the master model is overall supported by the temporary filler (59), the master model is not deflected downwardly.

Abstract: A method of fabricating a mold and a method of fabricating an article with the mold is disclosed that is capable of fabricating a high three-dimensional surface structure and extending the service life of the mold. A mold having a fine surface shape of a height less than an object height is fabricated, then the fine surface shape of the mold is transferred to an intermediate mold by dry-etching, and then the fine surface shape of the intermediate mold is further transferred to a final article material by dry-etching. In each transfer step by dry-etching, the etching selection ratio is appropriately adjusted to increase the height of the fine surface structure step by step, so that the fine surface shape of the final article material has the object height. On the surface of the final article material, a preliminary pattern of the object surface shape may be formed beforehand to reduce the required thickness of the curable resin.

Abstract: A method of manufacturing a magnetic stamper/imprinter for use in patterning of magnetic recording media by means of a contact printing process, comprising sequential steps of: (a) providing a stamper/imprinter comprising a body of a magnetic material having an imprinting surface including a topographical pattern corresponding to a pattern to be formed in the surface of a magnetic or magneto-optical (MO) recording medium and comprising a patterned plurality of spaced-apart recesses with a plurality of non-recessed areas therebetween, said imprinting surface including a plurality of defects comprising surface blemishes and stains, magnetic particles, and non-magnetic particles; (b) initially removing the surface blemishes, stains, and magnetic particles; and (c) then removing or rendering the non-magnetic particles benign to the contact printing process.

Abstract: A method for making a thermosetting polymer reproduction of an object preferably comprises the steps of modifying an original object such as an object found in nature (e.g., a stone or array of stones) or a manmade article (e.g., a carved decorative object) to a predetermined configuration, making a first mold of at least part of the surface of the original object, filling the first mold with a first thermosetting polymer material to produce a reproduction of at least part of the surface of the original object, modifying the reproduction to a predetermined configuration, making a second mold from the modified reproduction and filling this second mold with a thermosetting polymer material to produce a reproduction of at least part of the surface of the original object. The second mold can be used repeatedly to produce reproductions in commercial quantities.

Abstract: Methods of rapidly prototyping microstructures such as HARMs are disclosed. A high precision process uses polymeric microstructure replication techniques and sacrificial layer etching techniques to mass produce high aspect ratio metallic and polymer micromold inserts. In one embodiment, after fabrication of an initial micromold insert, high aspect ratio replications are created by casting replication material, such as PDMS, directly onto the initial micromold insert. The replicated HARM is coated with a sacrificial layer and then electroplated to replicate another set of micromold inserts. After the electroplating process is completed, the sacrificial layer is etched away to release the replicated micromold inserts.

Abstract: The present invention revolutionizes a scale modelers ability to quickly and easily create realistic scale roads or paved surfaces by allowing the said user to create said road or road system in any size, shape or configuration. This work is to be performed on a work bench thus saving much back and muscle ache(s) from the necessity to lean over a layout or scale model scene to create a road or road system in place. The present invention will remain flexible in it's completed form allowing for placement onto varying ground elevations and hill grades.

Abstract: An easy-to-grip diaper fastener tab has an array of hook-shaped fastener elements arranged in parallel rows, each fastener element including a stem and a crook extending from the stem in a predetermined direction to a distal tip. The array includes a plurality of rows of fastener elements arranged such that, in each row, all of the crooks face in the same direction and parallel to the direction of the row, with the crooks of adjacent rows facing in opposite directions. The longitudinal spacing between opposing tips of adjacent hooks of adjacent rows is greater in a first portion of the array than the longitudinal spacing between opposing tips of adjacent hooks of adjacent rows in a second portion of the array, such that the crooks of the hooks of the first portion are more exposed for engaging loops than the crooks of the hooks of the second portion. Methods and molds for forming such arrays are also provided.

Abstract: The invention concerns a process for producing a mold, wherein a hollow space is formed within a rigid mold frame (2) which corresponds to the shape of the component to be produced. According to the invention one fills the mold frame, with the exception of an area which surrounds and is in close proximity to the hollow space, with a plurality of filler elements (6), which are formed into at least an essentially incompressible shape. Subsequently, a model (8) of the component to be produced is introduced into the mold and the interstitial space between the model and the filler elements is filled with a masking material or mold shell forming material (4).

Abstract: A metal mold is machined via a computer numerically controlled wire-cut electrical discharge technique so as to describe a fractally profiled parallel grooves-and-ridges configuration. Fibers are placed along the mold's grooves. Using the mold combined with the fibers situate in its grooves, a first composite portion is resin transfer molded so as as to describe a complementary fractally profiled parallel grooves-and-ridges configuration, and to include, in its ridges, the fibers situate in the mold's grooves. Fibers are placed along the first composite portion's grooves. Using the first composite portion combined with the fibers situate in its grooves, a second composite portion is resin transfer molded so as as to describe a complementary fractally profiled parallel grooves-and-ridges configuration, and to include, in its ridges, the fibers situate in the first composite portion's grooves, and to effect secondary bonding of the first and second composite portions.

Abstract: The invention relates to a method and system for producing verified component designs and for assisting in tool design to near-production specification in the materials of choice, via production processes and in considerably shorter time scales than has previously been possible.

Abstract: An artwork is made on a surface of a matrix or plate with acrylic paint and then allowing the paint to dry. A layer of a backing material adhesive, such as an acrylic gel, is next applied to the acrylic layer and a backing material (such as paper or cloth) is placed upon the gel, and the wet gel is then allowed to dry. The dry artwork is then removed from the matrix. The invention allows the inclusion within a single image of other media (wet or dry), such as paper, fabric, dry acrylic elements, watercolor, waterbase crayons and pencils, felt pens, waterbase inks, water mixable oil paints, oil pastels and oil paint sticks because of the bonding abilities of acrylics.

Abstract: A process for fabricating a custom breast prosthesis or an intermediate casting form for a breast prosthesis, in which the task of creating the intermediate casting form is considerably simplified, and enables a shaping of the casting form, in situ.

Abstract: A method of replicating a structured surface that includes providing a tool having a structured surface having a surface morphology of a crystallized vapor deposited material; and replicating the structured surface of the tool to form a replicated article. A replicated article includes at least one replicated surface, wherein the replicated surface includes a replica of a crystallized vapor deposited material. A replication tool includes: a tool body that includes a tooling surface; and a structured surface on the tooling surface, wherein the structured surface includes crystallized vapor deposited material or a replica of crystallized vapor deposited material.

Abstract: A method for preparing a mold form includes forming a mold blank having a surface corresponding to the surface of the article desired and enclosing the mold blank in an open ended enclosure. A thin layer of polymer resin, preferably polyurea is sprayed on the surface of the mold blank and allowed to cure. Heat transfer tubing is inserted over the resin layer. A mixture of metallic pellets and epoxy are inserted over the heat transfer tubing and then another layer of resin is sprayed over the mixture. After the resin has cured, the mold blank is removed to expose the mold form having an outer surface of polyurea.

Abstract: A method of forming an injection molded epidermal abrasion device includes depositing mold material on an epidermal abrasion device. The epidermal abrasion device is separated from the mold material to yield a mold. An epidermal abrasion device is then formed within the mold. The epidermal abrasion device may include a matrix of isotropically etched structures having isotropically etched sidewalls positioned between wide bases and narrow tips, each isotropically etched structure having a vertical height of at least 20 &mgr;m. The matrix of isotropically etched structures may define a matrix of pyramids.

Abstract: A method is described comprising the steps of modifying a natural article to a predetermined configuration, making a mold of at least part of the modified natural article, filling the mold with a castable material to produce a reproduction of at least part of the surface of the modified natural article, modifying the reproduction to a predetermined configuration, making another mold from the modified reproduction and filling this mold with a castable material to produce another reproduction of at least part of the surface of the modified natural article; the second mold can be used to produce reproductions in commercial quantities.

Abstract: The invention relates to the process of forming a customized saddle tree mold to be used in turn as a model to make or select a saddle tree. The method or process involves the steps of warming a thermoplastic sheet to a pliable condition, applying the panel to the saddle area of a equine, while pliable, applying pressure against the outside of the panel to force the panel against the horse to change the shape of the panel to closely and accurately conform to the shape of the equine in the saddle area, allowing the panel to cool and harden in that shape so that it may be used in turn as a form or mold to shape or select a saddle tree for that equine, which saddle tree being shaped to the form will accurately and closely conform to the shape of that equine in the saddle area.

Abstract: There is disclosed a method for simulating a mould-imparted texture including applying a textured skin to a moulding from a pre-textured mould.

Abstract: This disclosure relates to a method for making a polymeric article mold, a method for making a polymeric article with that mold, and improved surface topography features for a polymeric article. A prototype article is formed and then coated with a thin conductive layer. The coated prototype article is then electroformed until nickel plated to a sufficient depth to define a nickel plating tool. After the prototype article has been removed from the mold face of the nickel tool, the tool can be used as a mold for forming finished polymeric articles which replicate the original prototype article. The use of fine topography features such as a dense upstanding stem array on the surface of the prototype article facilitates accurate and complete electroforming by increased surface area presentation. The disclosure also presents improvements to microreplicated surface structures such as stem arrays.

Abstract: A method of applying a decorative color to a thermoplastic strip suited for use to produce slats for blinds is characterized by the use of a heat sensitive printing paper of the type normally used to color the fabric material from which valances are generally made. By using that type of color transferring medium to color the thermoplastic slats it becomes possible, for instance, to manufacture blind slats having the same color as the fabric valance to be hung decoratively from the window for which the blind is to be installed. There is also disclosed a blind structure for attenuating the flapping noise produced when the slats enter in contact with each other.

Abstract: A resin (61) as a material of a resin mold is injected in a second resin filling space (57) from a resin injection hole (51) provided in a second back surface reinforcing member (50). When the resin overflows from a resin overflow hole (52), the injection of the resin is stopped, followed by curing of the resin. During the operation of the resin filling step, since a downward load equivalent to a total of a weight of the resin injected in the second resin filling space and the injection pressure is applied to the master model (30), there is a possibility that the master model be deflected downwardly; however, in actual, since the back surface of the master model is overall supported by the temporary filler (59), the master model is not deflected downwardly.

Abstract: A press forming die is fabricated by initially fabricating a die forming panel, by press forming, which provides a die surface for the press forming die. During fabricating the die forming panel, a shaped panel is obtained by initially press forming a first blank material with a die forming prototype and a punch forming prototype. Next, the shaped panel is mounted onto the punch forming prototype again and, thereafter, a die forming panel is obtained by press forming a second blank material. The die forming panel is then mounted on a frame body and a backup material is formed between a space between the frame body and the die forming panel, thereby fabricating the press forming die. Since the die surface of the press forming die can be shaped by press forming, the press forming die can be simply fabricated.

Abstract: In a display device for an electronic apparatus, a circular polarizing plate constituted by a linear polarizing plate 42 and a ¼&lgr; plate 43 is provided between a solar display board 41 and a middle frame 46 for fixing a module 45 having a solar cell 44 to an outer case. As a result, a boundary line between the middle frame 46 and the solar cell 44, a gate track generated through injection molding of the middle frame 46, and further more, a solar cell element dividing line of the solar cell 44 cannot be seen. Consequently, a variation in design of the solar display board 41 can be increased. Moreover, the color of the solar display board 41 is deepened so that a feeling of high quality can be obtained as goods, and the provision of the middle frame can provide various external shapes of a watch in respect of the design.

Abstract: Disclosed are a shaping mold for producing an optical fiber guide block which permits highly accurate positioning and fixing of optical fibers, an optical fiber guide block having such excellent properties, processes for the production of these, and an optical fiber array.

Abstract: The present invention relates to the fabrication of elastomeric replicas or stamps of surfaces from a stamp master, wherein the master has geometrical features below 100 &mgr;m. The elastomeric stamps of the present invention are prepared from injection-molded plastic stamp masters. The stamps are used to replicate the surfaces or patterns of the stamp master on a substrate using soft lithography techniques.

Abstract: This patent application describes the use of molecular imprinting as a means for preparation of anti-idiotypic imprint matrices. With this technique, imprints of artificial or natural molecules including their recognition sites, such as of molecularly imprinted polymers or biological receptors, antibodies or enzymes, can be prepared. In the former case, using the original imprints as casts or molds in a subsequent polymerisation step, utilising preferentially functionally complementary monomers, the formation of imprint materials containing recognition sites complementary in shape and functionality with the original imprint can be obtained but being of different composition. Alternatively, imprints or images of the artificial or biological species can be obtained directly. The so formed preparations can be used in a vast variety of applications, e.g. as new drugs, inhibitors or new affinity materials.

Abstract: A process is described for making gourd molds useful in the production of decorative ceramic and other articles which bear the textures of the gourd interior. Articles produced may also serve as models for use in the manufacture of production molds. Steps in making the gourd molds include selection, cutting, and removal of pulp; steps in using the gourd molds include treating with a release agent, casting, and removal of the gourd mold from the molded article.

Abstract: A method of making molds for the production of golf balls is disclosed. A hob is made having an imperfectly spherical arcuate surface that is composed of at least two different arcs in continuous arrangement to each other. A mold half is formed using the hob so that the imperfectly spherical hob creates an imperfectly spherical golf ball cavity within the mold half. When used to make golf balls, the imperfectly spherical cavity results in golf balls having a higher degree of sphericity than golf balls made by spherical hobs and mold half cavities.

Abstract: A method for fabricating a decorative window insert, and from the insert a decorative window, comprises the steps of producing a plurality of planar glass units each adapted by size and shape, for assembly together as a decorative insert master by assembling the planar glass units into a planar assembly wherein the planar glass units are joined by a came, producing a mold from the decorative insert master, the mold replicating the decorative insert master with a came mold portion and a planar glass units mold portion, filling the came mold portion of the mold with a dyed catalyzed resin and curing the resin as a simulated came portion of the insert, filling a planar glass units mold portion of the mold with a non-dyed catalyzed resin and curing it as a simulated glass portion of the insert followed by a post-curing of the simulated came portion and the simulated glass portion to produce the decorative window insert.

Abstract: Methods and apparatus useful in the development of molds are disclosed. In particular, the methods and apparatus of the present invention are useful, for example, in the context of dimensionally expanding and printing a picture image on a printable sheet for use in making a picture print thermoforming female mold of castible shrinkable material. In addition, a process for producing a male mold which replicates brush strokes of an original painting is disclosed.

Abstract: Replicas are molded by curing a photo-curable liquid silicone rubber composition to form a transparent mother mold having a cavity corresponding to the outer contour of a master model, casting a photo-curable liquid resin into the mold cavity, and irradiating light to the liquid resin through the mold wall. Replicas can be fabricated by simple steps and within a short time.

Abstract: A nozzle plate, particularly for fuel injection valves, with at least one flow path which has at least one supply opening, which path includes a ring gap which opens into a ring-shaped exit opening, as well as a method for the production of such a nozzle plate. For the nozzle plate, it is provided that the flow path has a ring channel assigned to the supply opening, which channel makes a transition into a cylinder-shaped ring gap with a cross-section which narrows in the region of the exit opening. The production of the nozzle plate takes place in that a cavity mold corresponding to the flow path through the nozzle plate is produced, that a layer embedding the cavity mold is galvanically deposited, and that the cavity mold is removed from the galvanically deposited layer.

Abstract: A cushioning sole for use in contact with a foot, the foot being characterized by a specific shape relief and pressure map. The cushioning structure comprises a central layer of a rubber-like thermoplastic material having an upper surface devised to be in contact with the foot and having a shape relief conforming the specific shape relief of the foot, and a bottom surface opposite the upper surface. The cushioning sole further comprises a layout of space-apart anatomical pressure-receiving fingers made integrally with the central layer and protruding from at least one of the upper surface and bottom surface. Each of the pressure-receiving fingers has a predetermined height and diameter. The layout, the height and the diameter of the pressure-receiving fingers are determined in function of the physical characteristics of the rubber-like thermoplastic material and the specific pressure map of the foot, whereby the overall pressure-receiving fingers suit the specific pressure map of the foot.

Abstract: A method for forming a glossy decorative laminate is disclosed. The method is achieved by stacking a decorative laminate sheet assembly having a top layer, casting a polypropylene release sheet wherein the polypropylene release sheet is processed with chill rollers treated in a manner which improves the gloss characteristics of the resulting decorative laminate, positioning the polypropylene release sheet on the top layer of the decorative laminate sheet assembly, applying heat and pressure to the decorative laminate sheet assembly and the polypropylene release sheet sufficient to bond the decorative laminate and releasably bond the polypropylene release sheet to the top layer of the decorative laminate sheet assembly, and removing the polypropylene release sheet from the top layer of the decorative laminate sheet assembly to reveal a decorative laminate exhibiting desirable gloss characteristics.

Abstract: A vehicle wheel cover (10) having a design (36) which replicates the intrinsic design (20) of a vehicle wheel (12), and which includes a central aperture (38) which encompasses a set of lug nuts located on the vehicle wheel (12). The wheel cover (10) also includes a plurality of spaced wheel cover fasteners (44). When the wheel cover (10) is pressed against the vehicle wheel (12) the wheel cover fasteners (44) clip onto a peripheral edge (14) on the vehicle wheel (12) to securely hold the wheel cover (10) to the vehicle wheel (12). When the wheel cover (10) is attached, the vehicle wheel simulates the appearance of a solid, chrome plated vehicle wheel.

Abstract: A soft plastic fishing lures may be made to float by incorporating air bubbles therein by methods and in molds that draw air from inside the molds in which the lures are cast.

Abstract: A method, process and apparatus for generating a stable, force-resisting positive or negative representation of a shape. A state-changeable mixture includes uniform, generally ordered, closely-spaced solid bodies and a liquid carrier medium of relatively similar density, with the liquid medium filling any voids or interstices between the bodies and excluding air or gas bubbles from the mixture. Within the mixture, the solid bodies can be caused to transition from a near-liquid or fluent condition of mobility to a stable, force-resisting condition through introduction and then extraction of a slight excess quantity of the carrier medium. To create mobility, this excess quantity or transition liquid is introduced to create a fluent condition by providing a slight clearance between the bodies which permits the gently-forced introduction of at least two simultaneous slip planes between ordered bulk masses of the bodies at any point in the mixture.

Abstract: The invention relates to a process for the preparation of molecularly imprinted polymers useful for separation of enzymes, which comprises the steps of reacting a complex of enzyme and affinity monomer, a comonomer and a crosslinker, with a polymerization initiator and a polymerization accelerator at ambient temperature and pressure for a period ranging between 2 to 24 hrs, thereby obtaining a crosslinked polymer, crushing the cross linked polymer obtained to fine particles, adding a solvent and extracting imprinted enzyme from the polymer, obtaining the molecularly imprinted polymer, contacting the imprinted polymer with aqueous solution containing imprinted enzyme or a mixture of imprinted enzyme and other enzymes and isolating the enzyme-adsorbed polymer.

Abstract: The present invention relates to a mold for a chemically curable composition including a first shell component, a second shell component and a honeycomb core interposed therebetween. The invention further relates to providing an essentially adiabatic environment for chemically cured compositions using the previously described mold.

Abstract: A method is provided for fabricating a cure tool for curing materials at elevated temperatures. A facility tool is formed having a tool surface defining a mold line corresponding to a pattern of the object to be molded, to which a release coating is then applied. A mixture of a first resin surface coating is then prepared and de-aired to remove air trapped therein before being applied to the tool surface of the facility tool. The layer of the first mixture is then allowed to tack off for a predetermined period of time before being re-smoothed to promote substantially even application thereof to the tool surface. A mixture of a second resin surface coating is then prepared, preferably having a mix ratio by mass of about half the mix ratio by mass of the first mixture, and then de-aired to remove air trapped therein. A layer of the second mixture is then applied to the layer of the first mixture after the layer of the first mixture has tacked off.

Abstract: The method of making a dry film decorative panel covered with paint or covered with metal or plastic sheet film designed to look like metal includes providing a substrate, at least one sheet of dry photoresist film, developer wash for the dry film and at least one art work stencil. Preferably, any line art work can be utilized as the art work stencil. The dry film is placed intermediate the art work and on the substrate thereby forming a layered composite. The layered composite is exposed to UV light to polymerize the exposed areas. The art work is thereafter removed. Non-UV exposed dry film layer portions are washed away utilizing developer wash. The resulting UV exposed and polymerized dry film portions create relies on the substrate. Multiple layer relies are created by repeating the aforementioned steps. The relief and supporting substrate is painted to form a decorative panel or is covered with metal or metal-like plastic sheet foil.

Abstract: A process and plant for producing boards of wood-based materials having either a structured upper surface or a smooth upper surface. The plant has a continuously operating production press and a continuously operating embossing press. A discharge section and a transfer section are located between the continuously operating production press and embossing press. The continuously operating production press compresses and cures a mat of pressing stock to create a board that retains heat, while the continuously operating embossing press imparts the permanent embossed pattern on an upper surface of a board. The transfer section has a water spray device and a covered steam hood for cooling the board and producing steam.

Abstract: Replicas are molded by curing a photo-curable liquid silicone rubber composition to form a transparent mother mold having a cavity corresponding to the outer contour of a master model, casting a photo-curable liquid resin into the mold cavity, and irradiating light to the liquid resin through the mold wall. Replicas can be fabricated by simple steps and within a short time.

Abstract: A thermosetting resin and filler composition that can be cured in a variety of shapes and dimensions to make a variety of tools is described. One example of a tool that can made is a vacuum-casting mold. One embodiment first involves forming a tool composition comprising (a) from about 65 to about 75 weight percent filler, the filler being selected from the group consisting of Group II metal carbonates, such as calcium carbonate and magnesium carbonate, alumina, silica, ceramic materials, glass, nut shells, fiberglass, dolomite, and mixtures thereof, (b) from about 25 to about 35 weight percent of a thermosetting resin, and (c) a catalyst for catalyzing the formation of the thermoset resin. Once formed, the tool composition is applied to a plug shaped so that the desired tool is formed by curing the composition on, around and/or in the plug. The composition is allowed to cure to form the tool, and the tool is then separated from the plug.

Abstract: A mechanical fastener. A preferred embodiment of the invention provides a mechanical fastener including engaging stems having heads with demarcation lines. The present invention also provides a method of making a mechanical fastener that includes placing a layer of heated material on stem ends to soften the stem ends and deforming the softened stem ends into convex heads.

Abstract: A seamless plastic pressure vessel having a heat exchanger encased therein is disclosed. The pressure vessel is a unitary seamless wall and the wall surrounds a heat exchanger unit comprising a length of hollow tubing having ends retained in a mounting fitting. The pressure vessel may be formed by a rotational casting or blow molding technique.

Abstract: A method of making a mold includes the steps of determining the contours of the part to be produced, forming pattern stations having a surface conforming to a contour of the part at a given location, placing the stations in spaced apart relationship, filling the spaces, vacuum forming a plastic material to a portion and applying a mold making material. An alternative method includes the steps of determining the contours of the part to be produced, forming pattern stations each having a surface conforming to a contour of the part at a given location, joining the stations together such that their surfaces form substantially the complete contour of the part and covering a portion of the pattern with a plastic material. The stations may be releasably joined together such that one or more may be removed and substituted with one or more different stations.

Abstract: A blur film is made of a polymeric film material transmissive to infrared energy of a selected waveband, which is affixed to a surface of a substrate transmissive to energy of the same selected infrared waveband. The blur film has a texture or a plurality of lenslets thereon, where the surface of each lenslet is a surface of revolution. In a spatial-filter wheel application, the blur film and substrate are affixed to a support, which in turn is rotatably mounted on a drive. The support is structured such that a portion of its circumference is covered by the blur film and a portion of its circumference is not covered by the blur film. The spatial-filter wheel is rotated in front of a detector to produce alternating blurred and direct images on the detector.

Abstract: A ceramic investment shell mold is reinforced with a carbon based fibrous reinforcement having an extremely high tensile strength that increases as the mold temperature is increased especially within the range of casting temperatures employed for casting large directionally solidified industrial gas turbine components. The carbon based fibrous reinforcement is wrapped or otherwise positioned around the repeating ceramic slurry/stucco layers forming the intermediate thickness of the shell mold wall. The reinforced shell mold can be used to cast large directionally solidified industrial gas turbine components with accurate dimensional control.