US 11,992,976 B2
Techniques for casting from additively fabricated molds and related systems and methods
Alex McCarthy, Watertown, MA (US); Maxim Lobovsky, Cambridge, MA (US); and Martin Galese, Newton, MA (US)
Assigned to Formlabs, Inc., Somerville, MA (US)
Filed by Formlabs, Inc., Somerville, MA (US)
Filed on Jul. 13, 2021, as Appl. No. 17/374,037.
Application 17/374,037 is a division of application No. 15/981,279, filed on May 16, 2018, granted, now 11,097,449.
Claims priority of provisional application 62/507,661, filed on May 17, 2017.
Claims priority of provisional application 62/507,673, filed on May 17, 2017.
Prior Publication US 2021/0339432 A1, Nov. 4, 2021
Int. Cl. B33Y 10/00 (2015.01); B22D 18/06 (2006.01); B22D 29/00 (2006.01); B28B 7/34 (2006.01); B29C 33/00 (2006.01); B29C 33/38 (2006.01); B29C 33/40 (2006.01); B29C 33/52 (2006.01); B29C 33/56 (2006.01); B29C 39/26 (2006.01); B29C 39/36 (2006.01); B29C 64/112 (2017.01); B29C 64/129 (2017.01); B29C 39/24 (2006.01); B29K 71/00 (2006.01); B29K 503/08 (2006.01)
CPC B29C 33/3842 (2013.01) [B22D 29/00 (2013.01); B28B 7/346 (2013.01); B29C 33/0011 (2013.01); B29C 33/3807 (2013.01); B29C 33/3814 (2013.01); B29C 33/40 (2013.01); B29C 33/52 (2013.01); B29C 33/565 (2013.01); B29C 39/26 (2013.01); B29C 39/36 (2013.01); B29C 64/112 (2017.08); B29C 64/129 (2017.08); B33Y 10/00 (2014.12); B29C 2033/385 (2013.01); B29C 39/24 (2013.01); B29K 2071/00 (2013.01); B29K 2503/08 (2013.01); B29K 2901/10 (2013.01)] 11 Claims
OG exemplary drawing
 
1. A method of casting an object from a mold, the method comprising:
obtaining a mold comprising a hollow shell of rigid material, the rigid material comprising a thermoset polymer and one or more additives dispersed within the thermoset polymer,
removing at least some of the one or more additives from the hollow shell, thereby producing a plurality of pores forming an open cell network therein;
providing a metal and/or ceramic slurry into an interior of the mold; and
exposing at least part of the mold to a low pressure environment so that a net flow of gas is produced from the interior of the mold into the low pressure environment through the plurality of pores.