Scott R Morris

US Patent:

20180009128, Jan 11, 2018

Filed:

Jul 7, 2017

Appl. No.:

15/644268

Inventors:

- Fairborn OH, US
Ricky Lynn Pressley - Indiantown FL, US
Bryan Deptowicz - Beavercreek OH, US
Scott Morris - Columbus OH, US

International Classification:

B28B 1/00
B22C 9/24
B22C 9/10
B28B 17/00

Abstract:

A disclosed system includes an additive manufacturing printer that performs a layer by layer three-dimensional printing process generating a casting mold based on a three-dimensional numerical specification. The numerical specification is based on a desired casting shape, including internal features such as hollow areas formed by cores, and is further based on a thermo-mechanical model of a casting process. The numerical specification describes variations in material and geometric properties of one or more layers of the casting mold corresponding to variations in the thermal and mechanical properties of the casting processes, as predicted by the thermo-mechanical model. The system may vary the thickness of features of the casting mold, based on predicted cooling rates, to reduce cooling non-uniformities and to provide for controlled, predictable cooling of the casting. The system may further generate trusses and heat sinks in the mold to respectively strengthen and weaken various features of the mold.