Additive fabrication technologies for creating molds for die components

Abstract

A method comprising the use of additive manufacturing techniques for creating molds and pattern parts for subsequent use in the casting of die components and die shoes for use in die stamping processes.

What is claimed is: 
     
         1 . A method of making a pattern part for use in casting a die component, comprising:
 (a) depositing a thin layer of polymeric powder on a build platform;   (b) selectively applying a solvent to particular regions of the thin layer of polymeric powder to bind the polymeric powder in said regions to define a cross-section of the pattern part;   repeating steps (a) and (b) to produce a completed pattern part having a configuration of the die component;   coating the pattern part with a slurry to form a shell about the pattern part;   heating the shell to harden the shell and vaporize the pattern part to create a shell comprising a negative image of the pattern part; and   casting a molten material into the shell to form the die component.   
     
     
         2 . The method of  claim 1 , wherein the step of depositing a thin layer of polymeric powder on a build platform further comprises:
 depositing a layer of polymeric powder comprising poly(methyl methacrylate).   
     
     
         3 . The method of  claim 2 , wherein the step of selectively applying a solvent to particular regions of the thin layer of polymeric powder further comprises:
 jetting droplets of the solvent on the thin layer of polymeric powder using a print head.   
     
     
         4 . The method of  claim 3 , further comprising:
 curing the pattern part.   
     
     
         5 . The method of  claim 4 , further comprising:
 impregnating the pattern part with a wax resin to seal the pattern part.   
     
     
         6 . The method of  claim 1 , wherein the step of coating the pattern part with a slurry to form a shell about the pattern part further comprises:
 coating the pattern part with a ceramic slurry.   
     
     
         7 . The method of  claim 4 , further comprising:
 dipping the pattern part in a fluidized bed of sand after coating the pattern part with the ceramic slurry.   
     
     
         8 . The method of  claim 1 , wherein the step of casting a molten material into the shell to form the die component further comprises:
 forming a die component having a near net-shape of the pattern part within an accuracy range of 1 mm to 5 mm.   
     
     
         9 . A method of making a die component, comprising:
 forming a mold core package using an additive manufacturing process, wherein the mold core package comprises a negative image of the die component;   casting a molten material into the mold core package; and   cooling the molten material to form the die component having a near net configuration of the mold core package within an accuracy range of 1 mm to 5 mm.   
     
     
         10 . The method of  claim 9 , wherein the set of forming a mold core package using an additive manufacturing process further comprises:
 (a) depositing a thin layer of particulate;   (b) selectively applying a binder to the thin layer to define a cross-section of a mold core package; and   repeating steps (a) and (b) to produce a completed mold core package.   
     
     
         11 . The method of  claim 10 , wherein the step of selectively applying a binder to the thin layer to define a cross-section of a mold core package further comprises:
 printing the binder on the thin layer using a three-dimensional sandprinting device.   
     
     
         12 . The method of  claim 11 , the step of cooling the molten material to form the die component having a near net configuration of the mold core package within an accuracy range of 1 mm to 5 mm further comprises:
 forming a die component having a near net configuration of the mold core package within 0.8 mm.   
     
     
         13 . The method of  claim 9 , wherein the step of forming a mold core package using an additive manufacturing process, wherein the mold core package comprises a negative image of the die component further comprises:
 forming a mold core package having a negative image of attachment features for attaching the die component to a die stamping assembly.   
     
     
         14 . The method of  claim 13 , wherein the step of forming a mold core package having a negative image of attachment features for attaching the die component to a die stamping assembly further comprises:
 forming a mold core package having a negative image of bores and counter bores.   
     
     
         15 . The method of  claim 9 , wherein the step of forming a mold core package using an additive manufacturing process, wherein the mold core package comprises a negative image of the die component further comprises:
 forming a mold core package having a negative image of a cutting edge.   
     
     
         16 . A method of making a plurality of sand mold packages for use in casting die components, comprising:
 printing a plurality of sand mold packages using an additive 3D printer wherein the plurality of sand mold packages comprises one or more die component configurations ;   nesting select sand mold packages from the plurality of sand mold packages into a casting structure having runners in communication with each select sand mold package;   casting a molten material into the casting structure to fill each select sand mold package using the runners; and   allowing the molten material to cool to form said die components having a near net configuration of each select sand mold package.   
     
     
         17 . The method of  claim 16 , wherein the step of printing a plurality of sand mold packages using an additive 3D printer further comprises:
 printing a plurality of sand mold packages in a range of about 80-150 sand mold packages in a single printing process.   
     
     
         18 . The method of  claim 16 , wherein the step of printing a plurality of sand mold packages using an additive 3D printer further comprises:
 printing runners in communication with each sand mold package of the plurality of sand mold packages.   
     
     
         19 . The method of  claim 16 , wherein the step of casting a molten material into the casting structure to fill each select sand mold package further comprises:
 casting tool steel into the casting structure.   
     
     
         20 . The method of  claim 16 , wherein the step of nesting select sand mold packages from the plurality of sand mold packages into a casting structure having runners in communication with each select sand mold package further comprises:
 using a cope and drag assembly to investment cast the molten material into the sand mold packages.