Abstract: A heat exchange module alone or part of a system including a control console. The HEM can include a channel enclosure assembly, a thermoelectric cooler (TEC) assembly and a heat transfer (cover) assembly. The enclosure assembly includes a channel for a heat-transfer liquid. The module can be constructed to provide for flexibility to better conform and fit on rounded and/or angular body parts and to efficiently transfer heat between the adjacent body part and the heat-transfer liquid via the TECs of the TEC assembly.

Abstract: A problem exists of prohibitively high costs associated with molds for small run, legacy, or prototype injection molded parts. Further, the lead time on molds is currently on the order of about two weeks. A mold is provided that is formed from three-dimensional printing. The mold includes a series of air and/or water cooling channels to limit thermal stresses to the mold. Additionally, a series of coatings is added to the surface of a 3D printed mold to extend the lifetime of the mold and increase the performance of the mold. The coatings perform a function other than to define a shape of an injection cavity, such as improving thermal conductivity, providing a thermal barrier between the injection material and the mold body, or improving the detachment of the final mold product from the mold body.

Abstract: Method and facility or apparatus for cutting a slipform cast hollow-core concrete product with water jet cutting, wherein in the outer surface of the fresh cast hollow-core concrete product is formed depressions or grooves in the areas to be cut with water jet cutting before curing of the hollow-core concrete product, which depressions or grooves extend in the area of the hollow-cores of the concrete product.

Abstract: An injection mold assembly for a high output consumer product injection molding machine, the injection mold assembly having a simplified cooling system that is an evaporative cooling system or a cooling system including a hazardous, dangerous, or expensive cooling fluid. The simplified cooling system has a cooling fluid channel that is confined to a mold support plate.

Abstract: An insert injection-molded case that provides a better appearance and a reduced defective rate of manufacture can be utilized for a number of products, including but not limited to a cover for portable communication devices. The case preferably includes: a metal plate having one or more fixing portions coupled to fixing members formed in a mold respectively; an injection-molded case body injection molded with the metal plate; and one or more holding portions formed in the injection-molded case body during the injection molding and coupled to the fixing members respectively to prevent deflection of the injection-molded case body caused during a cooling operation after the injection molding.

Abstract: An optical lens mold includes a mold body, a magnetic fluid, a plurality of thermocouples, a plurality of electromagnets, a controlling unit and a power source. The mold body defines a plurality of injection chambers and a cooling channel surrounding the plurality of injection chambers. The magnetic fluid contains magnetic particles and flows in the cooling channel. The thermocouples are capable of sensing temperatures of the plurality of injection chambers correspondingly. The electromagnets are positioned above the cooling channel corresponding to the plurality of thermocouples. The plurality of thermocouples and the plurality of electromagnets are connected to the controlling unit via the power source, the controlling unit is capable of the comparing the standard temperature value with temperature values sensed by the plurality of thermocouples, and maintaining the temperature of the plurality of injection chambers in a normal state.

Abstract: The invention relates to a molding tool for the production of components composed of fiber composite materials, in which the molding tool has a fiber composite structure and an electrical resistance heating element, whereby carbon fibers or carbon filaments are embedded into the fiber composite structure of the molding tool in a plastic matrix, close to the shaping surface of the molding tool. Such a molding tool is further developed in that the carbon fibers or carbon filaments in the plastic matrix, close to the shaping surface, essentially determine the mechanical strength of the molding tool, and that the electrical resistance heating element is interconnected in such a manner that at least individual sections of the electrical resistance heating element form an electrical parallel circuit with one another.

Abstract: A mold for molding a wind turbine blade, the mold comprising a mold body having a front molding surface and a rear face, the mold body having at least one tube therein for conveying a heating liquid therethrough, the at least one tube defining a plurality of laterally spaced heating elements, and a continuous layer of heat conductive material located in the thickness direction of the mold body between the plurality of laterally spaced heating elements and the front molding surface and extending laterally across the space between adjacent heating elements.

Abstract: A composite fabrication apparatus which may include a first tooling die and a second tooling die movable with respect to each other; a temperature control system having induction coils disposed in thermal contact with the first tooling die and the second tooling die; a first die susceptor provided on the first tooling die and a second die susceptor provided on the second tooling die and connected to the induction coils; and a cooling system disposed in thermal contact with the first tooling die and the second tooling die. A resin transfer system delivers resin from a resin source to the tooling dies to allow resin transfer molding. A composite fabrication method is also disclosed.

Abstract: A mold block includes a tool body with a contoured finished surface adapted to receive a tool insert having a forming surface for forming a bottle neck in a molding operation. The tool body defines an internal channel for heat transfer with the forming surface. At least a portion of the channel is offset generally equidistant from the finished surface to provide a path contoured for conformal cooling of the insert. The tool body has a pair of ports intersecting the channel. Several methods for forming a mold block are disclosed and include machining a contoured finished surface adapted to receive a tool insert on a tool body, forming a heat transfer channel within the tool body, and forming a pair of ports into the tool body. At least a portion of the channel is offset generally equidistant from the finished surface for conformal cooling of the insert.

Abstract: A composite fabrication apparatus which may include a first tooling die and a second tooling die movable with respect to each other; a thermal control system having induction coils disposed in thermal contact with the first tooling die and the second tooling die; a first die susceptor provided on the first tooling die and a second die susceptor provided on the second tooling die and connected to the induction coils; and a cooling system disposed in thermal contact with the first tooling die and the second tooling die. A composite fabrication method is also disclosed.

Abstract: An electroformed tooling device is disclosed. The device includes an electroformed tool with electrodeposited metal which has been plated from a structured substrate on a molding side to function as a molding surface and an uneven contour on a non-molding side of the electroformed tool left as a by-product of electroforming. The device also includes a blank base comprising a top surface, a network of thermal management channels, and at least a first opening and a second opening communicating with the network of thermal management channels to allow fluid to flow into the first opening and flow through the network of thermal management channels and flow out the second opening. The top surface further includes an electro-discharge machined contoured surface to mate with the uneven contour on the non-molding side of the electroformed tool. Fluid flowing through the thermal management channels cools or alternately cools and heats the electroformed tool.

Abstract: Disclosed is a temperature regulated vessel, and method for using the same, having a body configured to melt meltable material received therein, and one or more temperature regulating lines within the body configured to flow a liquid therein for regulating a temperature of the meltable material received in the melting portion. The vessel has a poor or low thermally conductive material on one or more of its parts, such as on the melting portion, on exterior surfaces of the body, and/or surrounding the temperature regulating lines to increase melt temperature of the material. The melting portion can also have indentations in its surface, and low thermally conductive material can be provided in the indentations. The vessel can be used to melt amorphous alloys, for example.

Abstract: A mould for moulding a wind turbine blade, the mould comprising a mould body having a front moulding surface and a rear face, the mould body having at least one tube therein for conveying a heating liquid therethrough, the at least one tube defining a plurality of laterally spaced heating elements, and a continuous layer of heat conductive material located in the thickness direction of the mould body between the plurality of laterally spaced heating elements and the front moulding surface and extending laterally across the space between adjacent heating elements.

Abstract: A device for shaping a workpiece is provided. The device includes at least one first and one second component between which the workpiece to be shaped can be molded under the effect of heat. The design and/or the material properties of the first and/or the second component are selected such that the component's thermal expansion is different in different directions.

Abstract: Method and apparatus for preparing of at least one ceramic shaped part. A cavity is provided between at least one external shape and at least one internal shape. A Si-containing powder composition is then provided in the cavity. The composition is then heated in a reactive gas atmosphere to obtain a reaction bounded ceramic shaped part. Use of the apparatus is also described.

Abstract: In one embodiment, a tool for forming an article in a molding operation has a tool body formed from a non-particulate material, with a particulate material bonded to the body. The body provides a forming surface for forming the article. The particulate material, or the particulate material and the tool body collectively provide a duct for conveying a fluid for transfer of heat with the forming surface. In another embodiment, the tool has a tool body formed from a non-particulate material with a cavity and the particulate material is disposed within the cavity. A heat transfer material is disposed in the cavity bonding the particulate material to the tool body. Methods for manufacturing such tools are also disclosed.

Abstract: An apparatus and method for molding composite material with a selectable uniform predetermined temperature during most of the curing time. The mold apparatus has two cooperating and complementing mold bed assemblies hingedly mounted to each other and movable between two extreme positions, open and closed. A composite inner skin and outer skins sandwich a spacer in between. The spacer member includes interconnecting passages throughout. An outer perforated composite skin member covers the spacer member. A source for pressurized gas is applied to the mold assemblies when in the closed position. A predetermined cooperative temperature is selectably used to uniformly control the curing characteristics of the first and second skin members as the pressurized hot gas or air forced to pass through the outer skin and the spacer member adjacent to the inner skin thereby exposing the form being molded to a uniform temperature gradient.

Abstract: A heat insulating stamper is disclosed. The heat insulating stamper includes an uppermost section made of a metal material, a lowermost section made of the same material as the uppermost section, and a middle section having a heat conductivity lower than the uppermost section. The middle section includes the same metal material as the uppermost section and the lowermost section, and heat insulating portions.

Abstract: A mold system has a hollow outer mold part extending along a mold axis, a hollow inner mold part inside the outer mold part and forming therewith an elongated cup-shaped cavity adapted to hold a plastic mass for the production of a preform, and a cooling tube extending coaxially inside the hollow inner part and forming a passage having an inner portion inside the tube and an annular-section outer portion outside the tube and between an outer surface of the tube and an inner surface of the inner mold part. A cooler circulates a coolant fluid through the passage. A plurality of angularly spaced and generally axially extending support ribs extend radially from one of the surfaces toward the other surface in the outer passage portion.

Abstract: The present invention relates to apparatus and methods of vibration. In particular, the present invention relates to apparatus and methods of vibration for tooling in a structure, such as, for example, a fuselage. In one implementation, the tooling comprises at least two conductors that create a force to vibrate the media in the tooling, which improves the compaction of the media in the tooling and the extraction of the media from the tooling. Other implementations may be used for compaction and/or extraction of the media in the tooling.

Abstract: Hollow nickel blow molds produced by nickel vapor deposition have an inner wall defining a mold cavity and an integral outer wall defining a hollow interior therebetween for coolant fluid. The outerwall has inlet and outlet ports therein for admission and exhaustion of the coolant fluid. A holder is provided for mounting the molds in a blow molding machine.

Abstract: An overmolding insert includes a base having at least one opening in a first surface, the opening communicating with a second surface opposite the first surface, at least one hollow projection extending from the first surface, the hollow projection having a first opening communicating with the opening of the first surface and a second opening located at a terminal portion of the hollow projection, the insert further having two opposed side walls, each side wall being joined to the first surface, two opposed end walls being joined to an opposite end of the first surface and extending from one side wall to the other side wall. The side walls, the end walls, and the first surface define a partially closed space, with the terminal portion of the hollow projection extending beyond the partially closed space.

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: Described are molds, dies and forming tools comprising: a) a heat exchanging body support member; and b) within the support member, a molding cavity portion formed by thermal spraying metallic particles to a desired configuration in the support member. Also described are methods of making a mold, die or forming tool comprising the steps of: a) providing a body support member having a controlled and designed porosity which permits the enhancement of the heat transfer ability of said mold, die or forming tool; b) configuring a surface of the support member to a desired cavity; and c) spraying particles to the configured cavity in the support member, thereby producing a mold, die or forming tool. Preferably, the materials of construction are metallic and are applied by thermal plasma spraying. The particles may also be ceramics, metal matrix composites, ceramic matrix composites, thermoplastic resins, thermoset resins, and composites based thereupon.

Abstract: Described are molds, dies and forming tools comprising: a) a heat exchanging body support member; and b) within the support member, a molding cavity portion formed by thermal spraying metallic particles to a desired configuration in the support member. Also described are methods of making a mold, die or forming tool comprising the steps of: a) providing a body support member having a controlled and designed porosity which permits the enhancement of the heat transfer ability of said mold, die or forming tool; b) configuring a surface of the support member to a desired cavity; and c) spraying particles to the configured cavity in the support member, thereby producing a mold, die or forming tool. Preferably, the materials of construction are metallic and are applied by thermal plasma spraying. The particles may also be ceramics, metal matrix composites, ceramic matrix composites, thermoplastic resins, thermoset resins, and composites based thereupon.

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 resinous die for press-shaping a blank material into a desired configuration, which comprises a die member and a mating punch, both having respective shaping portions. Each shaping portion is formed of an epoxy resin layer provided at portions thereof where a relatively low surface pressure is applied, and a plurality of reinforcing pieces provided in an embedded fashion at portions thereof where a relatively high surface pressure is applied, for reinforcing the shaping portion. This arrangement imparts increased durability to the shaping portion and hence the die while keeping the cost of manufacture of the die to a minimum.

Abstract: A mold for molding a core for use in casting hollow parts includes, a lower mold portion and an upper mold portion defining therein a cavity corresponding to the outer surface of the core. The lower mold portion includes a cutout disposed along a parting line defined between the lower mold portion and the upper mold portion and opening onto the cavity. After introduction of a ceramic slurry mixture into the mold the upper mold portion is removable, to expose a first side of the core and a protective flash formed in the cutout. Desirably, a heat shield is positioned over the protective flash and the exposed portion of the parting line of the lower mold portion so that the lower mold portion is not exposed directly to a flame during a preliminary firing to impart sufficient strength to the ceramic core so that the ceramic core may be handled.

Abstract: A resin mold has a surface layer formed on the molding surface of a main body from a thermosetting resin and containing fine particles of silicon carbide. The surface layer can be formed simply by thermosetting the resin without calling for any plating, so that the mold can be made in a short time. The high hardness of silicon carbide gives a high wear resistance to the surface layer. The main body is formed from a thermosetting resin and contains metal particles.

Abstract: A tool with conformal cooling channels is made by diffusion bonding several tool sections together, which enables the cooling channels to be made in virtually any desired configuration. Once the desired configuration of the cooling channels is determined, a block of tool material in an annealed state is cut into layers. Grooves are formed in the surfaces of the layers or holes are formed through the layers such that the grooves and holes will form the cooling channels when the layers are reconstituted into the block. Indexing holes or equivalent structure fixedly locates adjacent layers when they are reconstituted, and the grooves and holes are precisely located relative to the indexing holes, thus ensuring that the grooves and holes in facing surfaces of the layers form the desired channels. The layers are then diffusion bonded by pressing them together at an elevated temperature.

Abstract: A double-shell nickel mold produced by nickel vapor depositoin. A first nickel shell is deposited on a mandrel, heating/cooling lines are attached to the first nickel shell, a thermally-conductive filler is applied to fill all gaps between the heating/cooling lines and the first nickel shell, and a second nickel shell is deposited on the first nickel shell to encapsulate the heating/cooling lines.

Abstract: A mold assembly including moveable mold parts, one of which includes a plurality of hollow cavities. Each hollow cavity forms an outer wall of an elongated, generally annular portion of a molded part and the other mold part includes a corresponding plurality of core elements, which form an inner wall of the same portion of the molded part. Each core is disposed within a corresponding cavity to define a generally annular mold chamber portion for receiving molten material to be molded to form the shape of the portion of the molded part. Each core element includes a cooling apparatus and each cavity includes an outside cavity-cooling device. Each core element includes a first portion made of high strength material and a tip portion made of material having a greater heat diffusivity and heat transfer coefficient than said first portion.

Abstract: A glassware forming mold that includes a body of heat conductive construction having a central portion with a forming surface for shaping molten glass and a peripheral portion spaced radially outwardly of the central portion. A plurality of coolant passages extend in a spaced array through the peripheral portion of the mold body, and liquid coolant is directed through such passages for extracting heat from the body by conduction from the forming surface. A plurality of openings extend axially into the body radially between at least some of the liquid coolant passages and the forming surface for retarding heat transfer from the forming surface to liquid coolant in the passages.

Abstract: The present invention broadly relates to the mechanical locking and constrainment of an active layer on a given solid surface, wherein the active layer is formed. In addition, disclosed herein is a macrostructured mold with improved heat-absorbing ability comprising a solid base and an active layer disposed on the solid base, wherein the active layer comprises a metal matrix composite formed by the process of infiltrating a powdered preform with a molten infiltrating alloy at an infiltrating temperature, wherein the solid base is formed from material with a melt temperature higher then said infiltration temperature. The solid base further contains one or a plurality of preformed grooves for circulation of cooling fluid, wherein the active layer seals the grooves in the solid base wherein the sealed grooves are designed to contain the cooling fluid thereby providing a mold with improved heat-absorbing ability.

Abstract: The present invention broadly relates to the mechanical locking and constrainment of an active layer on a given solid surface, wherein the active layer is formed. In addition, disclosed herein is a macrostructured mold with improved heat-absorbing ability comprising a solid base and an active layer disposed on the solid base, wherein the active layer comprises a metal matrix composite formed by the process of infiltrating a powdered preform with a molten infiltrating alloy at an infiltrating temperature, wherein the solid base is formed from material with a melt temperature higher than the infiltration temperature. The solid base further contains one or a plurality of preformed grooves for circulation of cooling fluid, wherein the active layer seals the grooves in the solid base wherein the sealed grooves are designed to contain the cooling fluid thereby providing a mold with improved heat-absorbing ability.

Abstract: A mould for manufacturing disc-like objects including at least two mould parts which are mutually movable between a closed position in which they bound a mould cavity, which mould cavity is connected to an injection conduit for admitting heated, plasticized plastic under pressure into said mould cavity, and an opened position in which a disc-like object can be removed. The mould also has a device for removing a central portion from a disc-like object to form a central hole present therein, which device comprises a cylindrical part which is movable in axial direction in the closed situation of the mould cavity. The mould has the feature that at least one of the two mould parts is tempered only in the middle zone of the mould cavity for tempering the inflowing plastic during the inflow thereof via the pressure line and thus during the filling of the mould cavity.

Abstract: The present invention provides a composite molding tool including a surface coat that comprises metal powders and mineral fillers, and a composition comprising a resin mixture and metallic fillers. The composition includes at least about 45% metallic fillers, based on the weight percent of the total composition.

Abstract: An injection mold for molding a spool with flanges at both ends of a shaft such that the inner wall surfaces of the flanges are not flawed, and the dimension between the flange inner wall surfaces is uniform and thus the flange inner wall surfaces are free from distortion, and further the cooling time is short and hence the molding cycle can be shortened. Two mold members for molding the outer periphery of the shaft of the spool and the inner wall surfaces of the flanges are formed of a material having relatively low thermal conductivity. A pair of mold members for molding the outer wall surfaces of the flanges are formed of a material having relatively high thermal conductivity at least at portions thereof that mold the outer wall surfaces of the flanges.

Abstract: Mold cycle time is accelerated by employing thermally insulating surface temperature boosters, which are of a minimum thickness to promote cooling by heat transfer through the boosters. According to the thermal transfer properties of the insulating boosters and the respective temperatures of the molten material and the dies, the temperature of the cavity surface is raised by contact with the molten material to equal or exceed the temperature required to produce a molded article, preferably just until the time that the mold is fully filled. Heat transfer through the boosters to the dies then cools and solidifies the molded article until it can be removed from the mold. The temperature boosters result in increased cavity surface temperatures, such that the mold dies can be kept at substantially lower temperatures. The overall result is a reduction in mold cooling time and therefore acceleration of mold cycling.

Abstract: A method of slip casting wherein reduced pressure is applied to the mold during casting by virtue of a network of piping extending through the mold. The mold has an impermeable outer coating. Heat may also be applied to the mold during casting, by for example a heated fluid passing through piping located in the walls of the mold.

Abstract: The present invention broadly relates to the mechanical locking and constrainment of an active layer on a given solid surface, wherein the active layer is formed. In addition, disclosed herein is a macrostructured mold with improved heat-absorbing ability comprising a solid base and an active layer disposed on the solid base, wherein the active layer comprises a metal matrix composite formed by the process of infiltrating a powdered preform with a molten infiltrating alloy at an infiltrating temperature, wherein the solid base is formed from material with a melt temperature higher than the infiltration temperature. The solid base further contains one or a plurality of preformed grooves for circulation of cooling fluid, wherein the active layer seals the grooves in the solid base wherein the sealed grooves are designed to contain the cooling fluid thereby providing a mold with improved heat-absorbing ability.

Abstract: Processes for providing enhanced thermal properties of tooling, particularly metal and metal/ceramic molds, made by solid free form fabrication techniques, such as the three dimensional printing process, and the tooling made by these processes are disclosed. The methods of enhancing thermal properties include incorporating integral contour coolant channels into the mold, adding surface textures to the coolant channels, creating high thermal conductivity paths between the surfaces and the coolant channels, and creating low thermal inertia regions in the mold.

Abstract: A mold having a pair of mold halves defining a mold cavity for forming a glass container. There is an inner shell of the mold and an outer shell and a gap therebetween through which cooling gas flows. Heat transfer elements on the inner shell extend laterally outwardly from the inner shell into the gap for contact by cooling gas flowing through the gap thereby to cool the inner shell. The inner shell is formed from a hard material having a working temperature substantially greater than the melting temperature of glass, a heat conductivity of less than about 15 W/m-deg K, and a capability of generating at temperatures in excess of about 500.degree. C. a protective oxide film strongly adhered to the inner shell surface.

Abstract: In a temperature-controllable tool (11) or mould for producing plastic mouldings with at least one cavity (12) to accept the mould of the plastic moulding to be produced, at least one inlet or outlet aperture (13, 14) which are interconnected via channels (15) and form a temperature-control agent channel system for cooling or heating the mould cavity (12), the shot time (cycle time) is shortened, maintenance is made easier and higher quality injection-moulded components are obtained in that the run of the channels (15) is matched to the outer shape of the mould cavity (12) and the geometry of the channels (15) is matched to the temperature profile in the plastic moulding.

Abstract: A method and apparatus for producing a plastic article. The plastic is introduced into a mold that can be tempered and that has at least one hollow chamber, the contour of which corresponds to the outer contour of the article. During manufacture, the mold is heated up and removal of the article is effected with a cooled mold. To shorten the cycling time, the inner region of the mold that adjoins the hollow chamber is cooled and heated at least partially independently of the outer region that is remote from the hollow chamber, while the outer region is held at a temperature that is higher than the temperature during removal.

Abstract: Described are molds, dies and forming tools comprising: a) a heat exchanging body support member; and b) within the support member, a molding cavity portion formed by thermal spraying metallic particles to a desired configuration in the support member. Also described are methods of making a mold, die or forming tool comprising the steps of: a) providing a body support member having a controlled and designed porosity which permits the enhancement of the heat transfer ability of said mold, die or forming tool; b) configuring a surface of the support member to a desired cavity; and c) spraying particles to the configured cavity in the support member, thereby producing a mold, die or forming tool. Preferably, the materials of construction are metallic and are applied by thermal plasma spraying. The particles may also be ceramics, metal matrix composites, ceramic matrix composites, thermoplastic resins, thermoset resins, and composites based thereupon.

Abstract: A unitary mold member for shaping glass includes an inner surface which shapes molten glass blown thereagainst and an outer surface. A cavity within the unitary mold member is positioned between the inner and outer surfaces. The unitary mold member has passages at about the upper end thereof between the cavity and the surrounding atmosphere. The unitary mold member also has passages at about the lower end thereof between the cavity and the surrounding atmosphere.

Abstract: Described are molds, dies and forming tools comprising: a) a heat exchanging body support member; and b) within the support member, a molding cavity portion formed by thermal spraying metallic particles to a desired configuration in the support member. Also described are methods of making a mold, die or forming tool comprising the steps of: a) providing a body support member having a controlled and designed porosity which permits the enhancement of the heat transfer ability of said mold, die or forming tool; b) configuring a surface of the support member to a desired cavity; and c) spraying particles to the configured cavity in the support member, thereby producing a mold, die or forming tool. Preferably, the materials of construction are metallic and are applied by thermal plasma spraying. The particles may also be ceramics, metal matrix composites, ceramic matrix composites, thermoplastic resins, thermoset resins, and composites based thereupon.

Abstract: A casting is produced using a non-sand plastic core. The plastic core is made of a thermoplastic resin and set in a casting mold so as to form a cavity in the casting mold. A molten metal such as aluminum is poured under pressure into the cavity to form the casting (product). The plastic core maintains its initial shape during casting. The remaining heat of the casting or the solidifying metal causes the plastic core to melt after the casting so that the molten plastic core is easily removed.