US 12,377,460 B1
System and method for investment casting an object
Daniel J. Braley, O'Fallon, MO (US); Elaine MacDonald, Wildwood, MO (US); and Andrew Pfeiffer, Lake St. Louis, MO (US)
Assigned to The Boeing Company, Arlington, VA (US)
Filed by The Boeing Company, Arlington, VA (US)
Filed on May 29, 2024, as Appl. No. 18/676,646.
Int. Cl. B22D 25/02 (2006.01); B22C 9/02 (2006.01); B22D 37/00 (2006.01); B33Y 10/00 (2015.01); B33Y 30/00 (2015.01); B33Y 40/20 (2020.01); B33Y 50/02 (2015.01); B33Y 80/00 (2015.01); C04B 35/14 (2006.01); C04B 35/64 (2006.01)
CPC B22D 25/02 (2013.01) [B22C 9/02 (2013.01); B22D 37/00 (2013.01); B33Y 10/00 (2014.12); B33Y 30/00 (2014.12); B33Y 40/20 (2020.01); B33Y 50/02 (2014.12); B33Y 80/00 (2014.12); C04B 35/14 (2013.01); C04B 35/64 (2013.01); C04B 2235/6026 (2013.01); C04B 2235/612 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A method of making an object through investment casting, the method comprising:
additively manufacturing a mold for the object with a printing head on a carriage supported by a frame, wherein the mold is additively manufactured from a plurality of layers on a build platform supported by the frame;
machining an interior surface of the mold with a machining device on the carriage after a predetermined number of layers have been added to the mold through additive manufacturing; and
investment casting the object by directing a casting material from a feeder to a kiln supported by the frame and into the mold while the mold is supported by the build platform.
 
13. A hybrid investment casting assembly for making an object, the assembly comprising:
a frame;
an additive manufacturing portion including:
at least one printing head attached to a carriage and supported by the frame with the at least one printing head configured to move along an X-Y plane;
a build platform supported by the frame and configured to move along a Z-axis;
a machining device attached to the carriage; and
an actuated door to allow the carriage to translate in and out of a build chamber;
an investment casting portion including a feeder supported by the frame and configured to direct a casting material into a kiln supported by the frame; and
a controller configured to:
additively manufacture a mold for the object by directing a printing head on the carriage supported by the frame, wherein the mold is additively manufactured from a plurality of layers on the build platform supported by the frame;
machine an interior surface of the mold by directing a machining device on the carriage after a predetermined number of layers have been added to the mold through additive manufacturing; and
investment cast the object by directing the casting material into the mold while the mold is supported by the build platform.