The invention relates to a binder, which contains water glass and further a phosphate or a borate or both. The invention further relates to a method for constructing molds and cores layer by layer, the molds and cores comprising a construction material mixture, which at least comprises a refractory molding base material, and the binder. In order to produce the molds and cores layer by layer in 3-D printing, the refractory molding base material is applied layer by layer and is selectively printed with the binder layer by layer, and consequently a body corresponding to the molds or cores is constructed and the molds or cores are released after the unbonded construction material mixture has been removed.

A method is provided for casting a component. Accordingly, data indicative of at least one location of a unitary core-shell mold which is susceptible to a stress concentration is received. An additive manufacturing process is employed to form the unitary core-shell mold defining a casting cavity. The unitary core-shell mold includes a shell wall defining an outer component shape and a core wall positioned inward of the shell wall. The core wall defines an inner component shape. The core wall and/or the shell wall defines at least one reinforcement recess adjacent to the at least one location which is susceptible to the stress concentration. Following the forming of the unitary core-shell mold, at least one support member is positioned within the reinforcement recess in contact with the at least one location. With the support member in place, the component is cast within the casting cavity.

A description is given of the use of an additive mixture (A) for combination with a solution or dispersion (B) comprising waterglass, for producing a moulding material mixture for producing articles from the group consisting of foundry moulds and foundry cores; a multi-component binder system comprising (A) an additive mixture and (B) a solution or dispersion comprising waterglass; a moulding material mixture comprising a mould base material (C) and also components (A) and (B) of such a multi-component binder system; a method for producing an article from the group consisting of foundry moulds and foundry cores; articles from the group consisting of foundry moulds and foundry cores; and the use of such an article for metal casting, preferably for light metal casting, more particularly for aluminium casting.

A description is given of the use of an additive mixture (A) for combination with a solution or dispersion (B) comprising waterglass, for producing a moulding material mixture for producing articles from the group consisting of foundry moulds and foundry cores; a multi-component binder system comprising (A) an additive mixture and (B) a solution or dispersion comprising waterglass; a moulding material mixture comprising a mould base material (C) and also components (A) and (B) of such a multi-component binder system; a method for producing an article from the group consisting of foundry moulds and foundry cores; articles from the group consisting of foundry moulds and foundry cores; and the use of such an article for metal casting, preferably for light metal casting, more particularly for aluminium casting.

Sized molds for metal casting are obtained from molding material mixtures on the basis of inorganic bonding agents containing at least one phosphatic compound and at least one oxidic boron compound, especially sized, water glass-bound forms and cores, having at least one refractory base molding material, water glass as inorganic bonding agent and amorphous particulate silicon dioxide and one or more powdery oxidic boron compounds and one or more phosphatic compounds. The invention furthermore relates to a method for producing sized foundry mold bodies and use thereof, in particular for producing cast parts from iron alloys. The sizing is a water-based sizing.

The invention relates to a device and a method for producing components comprising a mould building device (1) for producing lost casting moulds, and a casting device (2) connected to the mould building device for casting components in the lost casting moulds, characterised in that the mould building device is suitable for the continuous layering of moulding plates (3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23), wherein a respective at least three of said moulding plates form a casting mould.

Foundry casting elements and methods of forming the same, the methods including: forming an aqueous slurry including an inorganic binder precursor, shaping the slurry using a pattern, curing the shaped slurry using a low temperature solidification process to form a casting element, and removing the pattern from the casting element.

A method for manufacturing a structure from a granular material, called sand, in particular a mold. A layer of sand is deposited. The layer of sand is selectively agglomerated by spraying, using a spray nozzle, an inorganic binder having an M2SiO3 type (meta)silicate dissolved in a solvent. Prior to the spraying, the inorganic binder is heated to a temperature to confer on it a viscosity less than 0.2 Pa.Math.s. A device for implementing the method is provided.

A method for manufacturing a structure from a granular material, called sand, in particular a mold. A layer of sand is deposited. The layer of sand is selectively agglomerated by spraying, using a spray nozzle, an inorganic binder having an M2SiO3 type (meta)silicate dissolved in a solvent. Prior to the spraying, the inorganic binder is heated to a temperature to confer on it a viscosity less than 0.2 Pa.Math.s. A device for implementing the method is provided.

An apparatus for manufacturing a three-dimensional article by additive manufacturing includes a processor and an information storage device storing software instructions. In response to execution by the processor, the software instructions cause the apparatus to: receive initial data defining the three-dimensional article having an outer surface, define a shell having the outer surface of the three-dimensional article and an opposing inner surface that defines an inner cavity, define a transition zone between the inner surface of the shell and a boundary that is inside the inner cavity and generally follows the inner surface of the shell, define a lattice of arrayed unit cells that fill the inside of the boundary, the lattice is defined by connected lattice segments, and define transition segments that couple the lattice to the inner surface of the shell.