Methods and systems for creating a mold for a cast memorialization product are described herein. In a process for creating a mold, a three-dimensional (3D) model of a product design is generated. The product design includes customized features for a memorialization product. A mold design is generated based upon the 3D model of the product design. Printing instructions for creating the mold are generated and accessed by a processing device. The mold is created according to the printing instructions. A product, such as a bronze memorialization product, can be cast using the mold.

A mold includes an ingot mold and a top core. The top core is disposed in and/or on the ingot mold. The top core forms, in part, a functional surface of a component formed in the mold and the ingot mold forms at least a sub-region of the functional surface of the component formed in the mold.

A mold includes an ingot mold and a top core. The top core is disposed in and/or on the ingot mold. The top core forms, in part, a functional surface of a component formed in the mold and the ingot mold forms at least a sub-region of the functional surface of the component formed in the mold.

A method for producing a cast component is provided. The method includes attaching a ceramic mold to a seed crystal body, the ceramic mold including a cavity defining the shape of the cast component and a seed crystal body interface having a complementary shape to the seed crystal body such that the seed crystal body may be capable of supporting the ceramic mold in a casting oven. The method also includes pouring a liquid metal into the mold such that the crystal seed portion contributes to controlled crystallization of the cast component.

A method for producing a cast component is provided. The method includes attaching a ceramic mold to a seed crystal body, the ceramic mold including a cavity defining the shape of the cast component and a seed crystal body interface having a complementary shape to the seed crystal body such that the seed crystal body may be capable of supporting the ceramic mold in a casting oven. The method also includes pouring a liquid metal into the mold such that the crystal seed portion contributes to controlled crystallization of the cast component.

A casting mould for casting complex-shaped castings from a molten metal. The casting mould has a mould cavity forming the casting and a delivery system that delivers molten metal into the mould cavity. The delivery system includes a sprue, a runner connected to the sprue and a feeder system connected to the runner. The mould cavity is connected to the feeder system or the runner via connections. When seen in the flow direction of the molten metal flowing from the sprue into the runner during the casting operation, the runner has a branch directed away from the sprue along the feeder system and has a directed-back branch adjoining the directed-away branch and guided along the feeder system in the opposite direction to the directed-away branch. The feeder system is connected to both the directed-away branch and the directed-back branch via two or more gates distributed along the respective branch.

A casting mould for casting complex-shaped castings from a molten metal. The casting mould has a mould cavity forming the casting and a delivery system that delivers molten metal into the mould cavity. The delivery system includes a sprue, a runner connected to the sprue and a feeder system connected to the runner. The mould cavity is connected to the feeder system or the runner via connections. When seen in the flow direction of the molten metal flowing from the sprue into the runner during the casting operation, the runner has a branch directed away from the sprue along the feeder system and has a directed-back branch adjoining the directed-away branch and guided along the feeder system in the opposite direction to the directed-away branch. The feeder system is connected to both the directed-away branch and the directed-back branch via two or more gates distributed along the respective branch.

A method for manufacturing a turbine blade 1, is provided. The method comprises the following steps: producing a shell and core assembly by additive manufacturing process, the shell and core assembly defining at least one internal cavity and having an internal structure corresponding to at least one internal cooling circuit of the turbine blade; pouring molten metal in the internal cavity of the shell and core assembly; solidifying the metal; removing the shell and core assembly.

A method for manufacturing a turbine blade 1, is provided. The method comprises the following steps: producing a shell and core assembly by additive manufacturing process, the shell and core assembly defining at least one internal cavity and having an internal structure corresponding to at least one internal cooling circuit of the turbine blade; pouring molten metal in the internal cavity of the shell and core assembly; solidifying the metal; removing the shell and core assembly.

A coupler having a support provided through the body of the coupler and a plurality of openings in the coupler which are configured as open cavities. The coupler structure includes a shank that has a vertical support as well as lateral support. The coupler may be configured with a double I-beam structure with openings into the shank. Cores that may be fixed to the mold may be used to form the coupler and produce the openings in the shank.