Michael Torres

US Patent:

61562505, Dec 5, 2000

Filed:

Jan 4, 1999

Appl. No.:

9/225129

Inventors:

Michael J. Torres - Oxford CT
Michael F. Wells - Bridgeport CT

Assignee:

MCP Metalspecialties, Inc. - Fairfield CT

International Classification:

B29C 3902

US Classification:

264102

Abstract:

Fully dense composite accurate tooling is manufactured by casting but without the requirement of subsequent machining. The tooling so provided by the invention comprises injection mold halves for mating engagement to form a mold for injecting multiple near net shapes using either thermoset or thermoplastic materials. A known vacuum casting technique used for producing parts has been modified to make tooling according to the invention. A master pattern of the near net shape or a model of the actual core and cavity of the desired mold is used to create a silicone rubber mold (SRM). Once the SRM is completed, the 3-part material (catalyst, resin and composite) is weighed to the required volume to cast into the SRM, then placed (along with the SRM) into the vacuum casting system which reaches a level of 28 inches Hg of vacuum. The 3-part composite material is thoroughly mixed for approximately 20 minutes in about 28 inches Hg of vacuum. Similarly, the composite mixture is automatically poured into the SRM at about 28 inches Hg of vacuum.