The present disclosure generally relates to casting molds including a casting core comprising a first metal component and a second metal component. In an aspect, the first metal component has a lower melting point than the second metal component. In another aspect, the second metal component surrounds at least a portion of the first metal component and defines a cavity in the casting core when the first metal component is removed and the second metal component is not removed.

The present disclosure generally relates to investment casting molds comprising a casting core comprising at least one graded core component, the graded core component comprising at least one graded transition between a first core material and a second core material.

The present disclosure generally relates to casting molds including a casting shell surrounding at least a portion of a casting core comprising a first metal component and a hot isostactic pressed second metal component around the first metal component. In one aspect, the first metal component may have a lower melting point than the second metal component. In another aspect, the second metal component may retain some metal powder grain structure.

There is provided a member of a mold stack (100, 800), the member comprising: a member body (102, 802) defining a member molding surface for defining, in use, a portion of a molding cavity for molding a molded article, a member cooling circuit (120, 820) having a plurality of member cooling channels (128, 829), the plurality of member cooling channels (128, 829) being coupled in parallel to a source of cooling fluid, the member cooling circuit (120, 820) being fully encapsulated within the member body (102, 802).

A method and an apparatus for additive casting of parts is disclosed. The method may include: depositing, on a build table, a first portion of a mold, such that, the depositing may be performed layer by layer; pouring liquid substance into the first portion of the mold to form a first casted layer; solidifying at least a portion of the first casted layer; depositing a second portion of the mold, on top of the first portion of the mold; pouring the liquid substance into the second portion of the mold to form a second casted layer, on top of at least a portion of the first casted layer; and solidifying at least a portion of the second casted layer. The method may further include joining the first and second casted layers prior to the pouring of a third casted layer.

A method and an apparatus for additive casting of parts is disclosed. The method may include: depositing, on a build table, a first portion of a mold, such that, the depositing may be performed layer by layer; pouring liquid substance into the first portion of the mold to form a first casted layer; solidifying at least a portion of the first casted layer; depositing a second portion of the mold, on top of the first portion of the mold; pouring the liquid substance into the second portion of the mold to form a second casted layer, on top of at least a portion of the first casted layer; and solidifying at least a portion of the second casted layer. The method may further include joining the first and second casted layers prior to the pouring of a third casted layer.

A method for producing a counter-form (20) for manufacturing a part having a complex shape (24) by pressure sintering densification. The counter-form (20) is formed from successive layers produced by numerically-controlled three-dimensional (3D) additive printing according to the following steps: numerically recording a three-dimensional negative of the part to be produced (24) in a control unit of a three-dimensional additive printing system in order to constitute the positive form of the counter-form to be produced; producing the counter-form (20) using a 3D additive printing technique. The part having a complex shape (24d) is then manufactured by pressure sintering, then separated from the counter-form which is also sintered (20).

Breakable three dimensional (3D) printed molds are disclosed. An example method for forming a mold having a cavity by creating a plurality of layers using an additive manufacturing process includes providing a build material; and controlling a fusion level of the build material separately for different layers of the plurality of layers to separately form the layers with a porosity corresponding to a target porosity.

Breakable three dimensional (3D) printed molds are disclosed. An example method for forming a mold having a cavity by creating a plurality of layers using an additive manufacturing process includes providing a build material; and controlling a fusion level of the build material separately for different layers of the plurality of layers to separately form the layers with a porosity corresponding to a target porosity.

A mold assembly includes a first mold part having guide passages defined therein. Protruding members are each movably received in a first portion of a respective guide passage to extend selectively in and out of the mold cavity. At least some of the protruding members are movable along different directions from one another. Cables are each connected to one of the protruding members and extend through a linear second portion of the respective guide passage and out of the first mold part. An actuator is connected to the cables and movable relative to the first mold part between an extended position and a retracted position. In the extended position, each protruding member protrudes into the mold cavity. In the retracted position, each of protruding member is retracted out of the mold cavity and contained within the respective guide passage. A guide element and a method of molding are also discussed.