US 12,420,481 B2
Method of producing patterns, molds, and related products
Kenneth J. Susnjara, Birdseye, IN (US)
Assigned to Thermwood Corporation, Dale, IN (US)
Filed by Thermwood Corporation, Dale, IN (US)
Filed on Nov. 14, 2024, as Appl. No. 18/947,443.
Application 18/947,443 is a continuation of application No. 18/325,833, filed on May 30, 2023, granted, now 12,172,369.
Application 18/325,833 is a continuation of application No. 17/661,202, filed on Apr. 28, 2022, granted, now 11,701,818, issued on Jul. 18, 2023.
Application 17/661,202 is a continuation of application No. 17/322,477, filed on May 17, 2021, granted, now 11,345,081, issued on May 31, 2022.
Prior Publication US 2025/0065560 A1, Feb. 27, 2025
Int. Cl. B29C 64/147 (2017.01); B29C 64/30 (2017.01); B33Y 10/00 (2015.01); B33Y 40/20 (2020.01); B29K 101/10 (2006.01)
CPC B29C 64/147 (2017.08) [B29C 64/30 (2017.08); B33Y 10/00 (2014.12); B33Y 40/20 (2020.01); B29K 2101/10 (2013.01)] 20 Claims
OG exemplary drawing
 
10. A method for manufacturing a part, the method comprising:
removing a porous material from a sheet to create a plurality of individual layer segments, with a CNC router;
forming each layer of a plurality of layers with the individual layer segments;
securing the layers together to form a part with a shape having a hollow interior;
placing a physical support within the hollow interior;
infusing the porous material of the part with a catalyzed thermoset material that is compatible with a porosity of the porous material by using a vacuum pump, by applying pressure, by dipping the part into the thermoset material, or by spraying the part with the thermoset material; and
removing material from an exterior of the part, with the CNC router, to form a part having a continuous surface and a hollow interior.