US 12,365,024 B2
Direct casting into droplet printed molds to create low surface finish AM parts
Eric S. Elton, Livermore, CA (US)
Assigned to Lawrence Livermore National Security, LLC, Livermore, CA (US)
Filed by LAWRENCE LIVERMORE NATIONAL SECURITY, LLC, Livermore, CA (US)
Filed on Aug. 2, 2023, as Appl. No. 18/364,315.
Prior Publication US 2025/0041934 A1, Feb. 6, 2025
Int. Cl. B22D 23/00 (2006.01); B22F 10/22 (2021.01); B33Y 10/00 (2015.01); B33Y 30/00 (2015.01)
CPC B22D 23/003 (2013.01) [B22F 10/22 (2021.01); B33Y 10/00 (2014.12); B33Y 30/00 (2014.12)] 5 Claims
OG exemplary drawing
 
1. An apparatus for direct casting into a mold, wherein the mold is adapted to create low surface finish additive manufacturing parts with reduced surface roughness in a subsequent casting operation, the apparatus, comprising:
a valve controller;
a liquid metal print head,
a high pressure gas supply line,
a pneumatic valve between said liquid metal print head and said high pressure gas supply line, and being responsive to the valve controller,
a build plate motion stage, and
the valve controller being configured to control the liquid metal print head to produce a stream of metal that is directed onto said build plate motion stage to produce the mold by metal droplets created from the stream of metal while falling toward the build plate motion stage, or upon landing on the build plate motion stage; and
the valve controller further being controlled to cause the liquid metal print head to produce an additional stream of metal to fill the mold once the mold is formed, and to heat an interior surface of the mold sufficiently to cause heat to permeate from the interior surface through to an outer surface of the mold, for a sufficient time, such that the heat partially melts an outer surface of the mold, wherein the melting of the outer surface of the mold smooths the outer surface to produce a reduced surface roughness of the outer surface of the mold.