A method of forming a cast component and a method of forming a casting mold is generally provided. The method is performed by plugging or covering an opening in a ceramic core-shell mold. The ceramic core-shell mold includes at least a first core portion, a first shell portion, and at least one first cavity between the core portion and the first shell portion. The core-shell mold may be manufactured using an additive manufacturing process. At least a portion of the ceramic core-shell mold and the plug or cover is coated with a second ceramic material.

A mold body for use in a mold includes a mold cavity, a chill cavity, a fill channel, and a chill material having a thermal conductivity that is greater than the thermal conductivity of the mold body disposed within the chill cavity. The chill cavity is formed adjacent the mold cavity and is separated from the mold cavity by a chill wall. The fill channel is in communication with the chill cavity and with an exterior surface of the mold body.

A mold body for use in a mold includes a mold cavity, a chill cavity, a fill channel, and a chill material having a thermal conductivity that is greater than the thermal conductivity of the mold body disposed within the chill cavity. The chill cavity is formed adjacent the mold cavity and is separated from the mold cavity by a chill wall. The fill channel is in communication with the chill cavity and with an exterior surface of the mold body.

According to some aspects, a method is provided of casting an object from a mold, the method comprising obtaining a mold comprising a hollow shell of rigid material, the material comprising a thermoset polymer having a plurality of pores formed therein, providing a metal and/or ceramic slurry into an interior of the mold, exposing at least part of the mold to a low pressure environment so that a net flow of gas is produced from the interior of the mold into the low pressure environment. According to some aspects, a method of forming a porous mold is provided. According to some aspects, a photocurable liquid composition is provided, comprising a liquid photopolymer resin, particles of a solid material, in an amount between 30% and 60% by volume of the composition, and a water-soluble liquid.

A process for forming a fluidic module (150) with integrated fluid separation includes positioning a first positive passage mold (115A) of a first fluid passage (170) having a tortuous shape within a volume of binder-coated ceramic powder (110A) and positioning a second positive passage mold (115B) of a second fluid passage (175) having a tortuous shape within the volume of ceramic powder (110A) and spaced apart from the first positive passage mold (115A). The process further includes positioning a powder interconnect (120) adjacent to a portion of each of the first (115A) and second positive passage molds (115B) within the volume of ceramic powder (110A), pressing the volume of ceramic powder (110A, HOB) with the first and second positive passage molds (115A, 115B) and the powder interconnect (120) inside to form a pressed body (148), heating the pressed body to remove the first and second positive passage molds (115A, 115B), and sintering the pressed body (148) to form a closed-porosity ceramic body (150).

A module and process for forming a ceramic fluidic module (300) that includes a unified closed-porosity ceramic body (200) and a tortuous fluid passage (P) that extends through the body (200). The body (200) has a first mean density within a first layer (222) that is greater than a second mean density within a second layer (226). The first and second layers (222, 226) are axially serially arranged between opposed major surfaces (228, 229) of the body (200). The fluid passage (P) adjoins the first layer (222) of the body (200). The process includes pressing a first volume of ceramic powder (120) to form a pre-pressed body (150). A passage mold (130) is then positioned on the pre-pressed body (150). The pre-pressed body (150) and the passage mold (130) are then covered with a second volume of ceramic powder (125). The body (150), the mold (130), and the second volume of ceramic powder (125) are then pressed to form a pressed body (160). The pressed body (160) is heated and sintered to form the ceramic fluidic module (300).

A method of manufacturing a ceramic matrix composite component includes casting a tool and placing a ceramic matrix composite layup on the tool. The method further includes sintering the ceramic matrix composite layup at a predetermined sintering temperature at atmospheric pressure while the ceramic matrix composite layup is supported on the tool.

The disclosure relates to methods of fabricating of a graphite powder mold, including: applying a base layer to an exposed surface of a mold having one or more features; depositing a graphite powder onto the base layer to fill the one or more features; applying a cover layer onto an exposed surface of the graphite powder, wherein the cover layer and the base layer join at intersecting surfaces encasing the graphite powder to form the graphite powder mold having one or more raised features

A device and a process for forming a monolithic substantially closed-porosity ceramic fluidic device having a tortuous fluid passage extending through the device, the tortuous fluid passage having a smooth interior surface, a material of the ceramic body having a continuous and uniform distribution of grains at least between opposed major surfaces of the ceramic body. The process includes positioning a positive fluid passage mold within a volume of binder-coated ceramic powder, pressing the volume of ceramic powder with the mold inside to form a pressed body, heating the pressed body to remove the mold, and sintering the pressed body. A relationship between a first stability characteristic of the volume of ceramic powder and a second stability characteristic of the mold prevents discontinuities in the pressed body after pressing and/or during heating.

A method for producing molded parts (16), a water-soluble casting mold (6) being produced in a first step using a layering method, in particular using a powder bed-based layering method. In a second step, the surface of the casting mold (6) is sealed with the aid of a material (9; 10). A casting of the molded part (16) is then formed by filling the casting mold (6) with a free-flowing, hardenable material (13), in particular a hydraulically setting material. After the casting has solidified, the casting mold (6) is dissolved with the aid of an aqueous solution (18), in particular a heated aqueous solution (18). The present application furthermore relates to a material system for producing a water-soluble casting mold (6), comprising at least one water-soluble material for building a casting mold (6) in a layering method, as well as comprising at least one material (9; 10) for sealing the surface of the casting mold (6).