A mold for use in a continuous caster is provided that includes a tubular structure having a plurality of wall structures. Each of the outer faces of the wall structures is configured to have reduced thicknesses centrally located between corners of the wall structures so as to provide rigidity to the tubular structure for handling thermal loads during a continuous casting process.

A cooling insert for a die, such as a distributor for a high pressure die casting assembly, and a method of manufacturing the cooling insert, is provided. The cooling insert can be formed of H13 tool steel and is manufactured using an investment casting process, for example, a process which uses a printed investment casting shell. The cooling insert includes complex cooling channels to improve cooling and reduce the duration of the casting process.

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 of working an additively manufactured part includes applying a layer of wax to a part manufactured with an additive manufacturing process. Then a mold is formed over the layer of wax on the part. The wax is then removed from between the mold and the part. The part is then melted in the mold, and then the part is re-solidified in the mold. Finally, the mold is removed.

Proposed are a method of manufacturing a metal product that uses an anodic aluminum oxide film and a patternable material together, in which a space where the metal product is manufactured is formed by the patternable material and the anodic aluminum oxide film provides structural support to the patternable material; and a mold using an anodic aluminum oxide film used therefor.

A method of optimizing strength in an improved mold for a cast component. The method may include the steps of evaluating a flaw in an existing mold, adding external reinforcement features to a design of the improved mold, manufacturing the improved mold in an additive manufacturing process, and casting the cast component in the improved mold.

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.

The present application provides a method of optimizing strength in an improved mold for a cast component. The method may include the steps of evaluating a flaw in an existing mold, adding external reinforcement features to a design of the improved mold, manufacturing the improved mold in an additive manufacturing process, and casting the cast component in the improved mold.